dp21l, 21s & 23s Maintenance Ver2

SERVICE MANUAL
Ver.2
DUPRINTER
DP-23S DP-21S DP-21L
Be sure to read this manual carefully, so that you repair and service this machine safely and correctly. Do not begin work until you have thoroughly understood the contents of this manual. Repairing or servicing the machine with insufficient knowledge about it could lead to unforeseen accidents or falls in the machine's performance or quality.
DUPLO SEIKO CORP.
Introduction
The cause of most accidents is failure to adhere to basic safety rules and observe safety instructions. It is important to prevent potential causes of accidents from occurring. In order to do so, read this manual carefully, and be sure to understand all the safety instructions and correct inspection and servicing procedures that it provides before beginning repair or servicing work. Repairing or servicing the machine with insufficient knowledge about it could lead to unforeseen accidents. It is not possible to anticipate and describe in a manual such as this every possible hazard that could arise in the course of repair and servicing. Therefore, besides observing the safety instructions marked in this manual and on the machine's labels, service personnel should be safety-conscious and take other safety precautions as necessary. When performing repair or service work not covered by this manual, you should obtain safety guidance from an appropriately knowledgeable person.
Copyright 2000 DUPLO SEIKO CORPORATION All Rights Reserved

1
D Using the service manual

This manual contains the following information: structure and function of major parts, disassembly and reassembly procedures, specifications, and procedures for adjustment, maintenance, inspection and corrective action. This information is current as of December 2000, and applies basically to the model DP-23S/DP-21S/DP-21L DUPRINTER. From time to time, parts are changed to improve quality, performance or safety. Note therefore that in some cases, certain parts or machine structure aspects described in the text or illustrations of this manual may not be precisely the same as the product being serviced. Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important for safety and must be observed.
'Safety-related instructions WARNING: If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury is likely to result.
CAUTION: If the instructions accompanying this symbol are ignored and the
machine is operated incorrectly, death or serious injury, or else material damage, is likely to result.
Examples of pictorial symbols

A " " symbol tells you that a certain action is forbidden. Precisely what is forbidden is indicated by a picture inside the symbol (in the example here, the picture means that disassembly is forbidden), or in writing at the side of the symbol. A " " symbol means that a certain action is forbidden and/or that a specific instruction must be followed. The specific instruction is indicated by a picture inside the symbol (in the example here, the instruction is "Remove the power plug from the socket").
'Service work-related instructions IMPORTANT: Draws attention to important information. If this information is ignored
and the machine is operated or serviced incorrectly, the machine`s performance could drop, or it could break down.
NOTE:
Draws attention to information that is useful for operation or maintenance of the machine, and to information about its performance, etc.
Safety instructions
Safety instructions
1. Cautions regarding the installation location
Safety instructions
Installation environment Avoid installing the machine in places exposed to direct sunlight. Sunlight will cause the temperature in the machine's interior to rise, possibly leading to malfunction of the control system. Sunlight could cause misoperation of the sensors. The heat of direct sunlight could cause deformation of the machine's plastic parts. * Also avoid installation near to a ground glass window; light and heat penetrate such windows although they are opaque. Avoid installing the machine in places subject to high or low temperature or humidity. High or low temperature or humidity could cause the machine to operate abnormally. Suitable temperature and humidity ranges are: Ambient temperature: Ambient humidity: 10y430y 40%470%
Optimum temperature and humidity: 20y, 65% If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless) parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl, leading to misfeeds or poor image quality. Avoid installing the machine in places with open flames, or where reflected heat or other hot air currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly. Avoid installing the machine in poorly ventilated places. Avoid installing the machine in dusty places. The machine should not be tilting when it is used. Install the machine so that it is level. (The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral direction.) Do not install the machine on shaky, sloping or otherwise unstable surfaces. The machine could fall over on such surfaces, or fall off them, causing injury.
Safety instructions
2. Cautions for installation work
Warning
The machine's power supply voltage and power consumption depend on the model. Details of this are given in the tables below. The power supply voltage and power consumption for the machine are given in the table below. The machine's power supply voltage is indicated on the identification plate located on the machine's left side; the machine must be connected to a power supply of the voltage indicated. a Otherwise, fire or electric shock could result. If the power supply voltage is unstable or if the power supply has insufficient capacity, the machine may not operate normally. Make sure that the power supply has sufficient capacity for the system as a whole, including optional equipment.
* 120V AC model
Power supply voltage With no load* At full load Power consumption Connect to outlet of 120V AC, 60Hz, at least 15A No more than 130V AC At least 110V AC
} Use power supply meeting these requirements
During platemaking : 190W During printing at speed 3 (printing speed) : 85W On standby : 15W
* 230V AC model
Power supply voltage With no load* At full load Power consumption Connect to outlet of 230V AC, 50Hz, at least 8A No more than 250V AC At least 210V AC
} Use power supply meeting these requirements
During platemaking : 190W During printing at speed 3 (printing speed) : 85W On standby : 15W
* "With no load" - when the machine is on standby. * "At full load" - when the machine is running at maximum power consumption.
Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected. Install the machine close to its power supply. The outlet used should be exclusively for the machine, and have no other equipment connected to it. If an extension cord is necessary, it should have a ground terminal, and be of the following ratings: * For a 120V AC model: 130V, at least 15A, length not exceeding 5m. * For a 230V AC model: 250V, at least 8A, length not exceeding 5m. Never tread on the power cord or pinch it between other objects, or accidents could result.
CAUTION
Install the machine in accordance with the installation procedure appended to this manual. Using the optional printer stand Lock the casters after the machine is installed. a Otherwise, the machine could move or fall over, causing injury. To move the machine, push it by its mounting base. a Pushing the printing (upper) part of the machine could make it fall over.
Safety instructions
3. Cautions for maintenance, inspection and servicing
Warning
' Precautions for safe servicing Always remove the power cord plug from the outlet before starting work. a Otherwise, you could get a shock or your hands/fingers could be injured. However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits). When motors are operated alone in function checks, interlocks are deactivated, so be aware of the conditions and positions of related equipment, and take great care not to put your hands or fingers into moving parts. The cutter unit contains hazardous sharp blades. Exercise great care when inspecting the cutter unit or replacing it or its parts. a Otherwise, your hands/fingers could be injured. Do not touch the drum or rollers after turning on the jog switch. Do not put your hands or fingers inside the machine while the drum is rotating. a Otherwise, your hands/fingers could get caught and crushed between the drum and rollers. If optional tape clusters are used The tape clusters have hazardous blades. Exercise care when inspecting or replacing the blades. a Otherwise, your hands/fingers could be injured.
' Working clothes Wear clothing than enables you to work safely.
CAUTION
' Tools Use tools that are appropriate for the work.
Safety instructions
DLocations of warning stickers

The locations of the machine's warning stickers are shown below. To ensure safe work, read the stickers and heed their instructions. Keep the stickers clean at all times. If they become damaged or peel off, replace them with new ones.
No. q w e r
Parts No. L1-T3060 L5-T3020 M7-T3030 L1-T3090
Name Warning Sticker 1 Warning Sticker 2 Warning Sticker 3 Caution Sticker
Q'ty 1 1 1 1
Introduction
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9

7
Description of the Operation
Mechanism
Standard / Adjustment
Installation
Maintenance / Check
Troubleshooting
HELP Mode
Others
Table of Contents
Introduction.................................................................................1 Using the service manual ..........................................................2 Safety instructions ...............................................................3 1.Cautions regarding the installation location........................3 2.Cautions for installation work ...............................................4 3.Cautions for maintenance, inspection and servicing .........5 Locations of warning stickers................................................6
Chapter 4
Standards / Adjustment
z Scanner Section.......................................................162 x Platemaking/Master Feed/Ejection Section...........163 c Paper Feed Section..................................................171 v Drum Driving Section ..............................................176 b Press Section ...........................................................178 n Paper Ejection Section ............................................180 m Drum Section ...........................................................182 , Electrical System .....................................................186 . Option .......................................................................193
Chapter 1
Introduction
z Features................................................................................12 x Specifications ......................................................................14 c Dimensions ..........................................................................16 v Mechanism ...........................................................................17 b Master ...................................................................................18 n Ink..........................................................................................19 m System Setup .......................................................................20 , Part Names and Their Functions........................................21 . Operation Procedures .........................................................29 0 Error Messages and Corrective Action .............................30 1 Option ...................................................................................52
Chapter 5
Installation
z DUPRINTER Installation Instructions ....................196
Chapter 6
Maintenance / Check
z Guaranteed Periodical Maintenance ......................208 x Cleaning and Oiling .................................................208 c Periodical Maintenance ...........................................209
Chapter 2
Chapter 7
Troubleshooting
z Scanner Section.........................................................56 x Platemaking/Master Feed/Ejection Section.............64 c Paper Feed Section....................................................84 v Drum Driving Section ................................................97 b Press Section ...........................................................103 n Paper Ejection Section ............................................106 m Drum Section ...........................................................111 , Option .......................................................................119
z Troubleshooting Guide............................................212 x Error Display ............................................................228
Chapter 8
HELP Mode
z HELP Mode List .......................................................230 x Overview...................................................................234 c HELP Mode Functions and Operation Procedures .......235 (1)Basic Procedure for Accessing HELP Modes...235
Chapter 3
Mechanism
(2)Guide to the HELP Mode Descriptions ..............235 HELP Mode Descriptions .....................................236
z Exterior .....................................................................122 x Scanner Section.......................................................127 c Platemaking/Master Feed/Ejection Section...........135 v Paper Feed Section..................................................144 b Drum Driving Section ..............................................148 n Paper Ejection Section ............................................150 m Drum Section ...........................................................153
Chapter 9
Others
z Electrical Parts Layout and Their Functions.........298 x Overall Wiring Layout..............................................305
1
Chapter 1 Introduction
z Features ........................................................................12 x Specifications...............................................................14 c Dimensions...................................................................16 v Mechanism ...................................................................17 b Master ...........................................................................18 n Ink..................................................................................19 m System Setup ...............................................................20 , Part Names and Their Functions................................21 1. Machine exteriors ....................................................21 2. Sectional (structural) view of the machine ...........24 3. Control Panel ..........................................................26 . Operation Procedures .................................................29 1. Printing.....................................................................29 0 Error Messages and Corrective Action......................30 1. Error messages .......................................................30 2. Corrective action .....................................................32 (1) Replacing the Ink Pack ......................................32 (2) Replacing the Master Roll .................................34 (3) Replacing the Master Ejection Core..................37 (4) Supplying Paper ................................................39 (5) Replacing the Drum Unit ..................................43 (6) Paper Jam (Feeder side).....................................45 (7) Paper Jam (Ejection side) ..................................46 (8) Master is Not Ejected.........................................49 (9) Master Set Incorrectly ("MASTER SET MISS"is displayed)..................51
1 Option ...........................................................................52 1. DUPRINTER Option .................................................52 (1) TAPE CLUSTER 4 .............................................52
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z Features
zFeatures
1. Size B4 printing (DP-23S) The DP-23S has size B4 (248X355mm) printing area. The DP-21L has size A4 (210X355mm) printing area. The DP-21S has size A4 (204X288mm) printing area. 2. High-speed platemaking With the DP-23S/21S/21L, it takes 25 seconds*1 to print the first sheet of paper.
*1: Time required to print the first sheet of paper after the platemaking key is pressed.
Size A/B models Zoom settings (70, 81, 86, 115, 122, 141%) Same-size (100%) printing
DP-23S Enlargement
141% [B5/B4, A5/A4] 122% [A4/B4, A5/B5] 115% [B5/A4] 86% [A3/B4, A4/B5] 81% [B4/A4, B5/A5] 70% [A3/A4, B4/B5]
Reduction
3. High print quality A new, originally-developed superfine thermal head gives beautifully accurate reproductions of fine print and halftone photographs. Its resolution is 300dpi in the main scanning direction and 600dpi in the sub scanning direction. 4. Align paper Adjusting the eject enables both thin and thick sheets of paper to be aligned neatly.
DP-21S Enlargement
141% [A5/A4] 122% [A5/B5] 115% [B5/A4] 86% [A4/B5] 81% [B4/A4] 70% [A3/A4, B4/B5]
Reduction
Inchi size model Zoom settings (64, 74, 77, 121, 129, 141%) Same-size (100%) printing
5. High-performance lamp A long-life, high-brightness xenon arc lamp is used to illuminate the documents. Since the lamp's intensity is not affected by temperature variation*2, printing quality at low temperatures is greatly enhanced*3.
*2: The lamp is filled with xenon gas, which means that it does not require heat to vaporize mercury, as a fluorescent lamp does, and therefore its intensity does not vary with temperature. *3: Increased viscosity of the ink at low temperatures results in fainter printing than at normal temperatures.
DP-23S Enlargement
141% 129% [ST/LTR] 121% 77% [LGL/LTR] 74% [LDG/LGL] 67% [LDG/LTR]
Reduction
DP-21S Enlargement
141% 129% [ST/LTR] 121% 77% [LGL/LTR] 74% 67% [LDG/LTR]
6. Full range of necessary functions qDocuments are easily enlarged or reduced. In addition to same-size printing, there are three automatic settings for both enlargement and reduction. The margin function (94% reduction) can be used with any setting.
Reduction
DP-21L Enlargement
141% 129% [ST/LTR] 121% 77% [LGL/LTR] 74% [LDG/LGL] 67% [LDG/LTR]
Reduction
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z Features
wSelf-diagnosis The machine has a self-diagnosis system, which notices user by flashing on and off a message and lighting up the relevant lamp when a expendable part needs replacing. eError message display An LCD panel displays error messages and messages prompting replenishment of consumables. r2 in 1 Layout mode This mode makes possible continuous printing of 2 documents onto single sheets of paper. tAdjusting the Printing Position (vertical) In addition to vertical direction adjustment. yKey card counter Raises the number of sections controlled to up to 200*4. Versions with internalized control panel also available.
*4: Standard: 30 sections. Using the counter (optional) raises the number to 200 sections.
7. Options qTAPE CLUSTER4 This permits sectionized printing, by inserting tape automatically during printing. wKEYCARD COUNTER4 This magnetic card can control the numbers of prints and platemakings by up to 200 sections. NOTE: Without this optional counter, the number of sections controlled is 30 (standard). eDrums Replacing the drum with optional drums permits printing with different colors. rOn-line functions*5 These enable data processed on a personal computer or word processor to be directly input and used for platemaking/printing.
*5: This function require PC interface.
uMemory function Allows 9 sets of memory settings.
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x Specifications
xSpecifications
Specifications
Product name/model No. Model Platemaking method Platemaking interval Resolution Scanning method ADF capacity ADF capacity Document type Document size Document thickness Reading width Printing area Feeding capacity Stacking capacity Paper size Paper thickness Printing speed DUPRINTER DP-23S Table top model Thermal digital platemaking 25 second(A4, same size) 300dpi(Main scanning direction)x600dpi(Sub scanning direction) ADF/movable document 100 sheets(64g/m2) Stencil printing Sheets Max. 291 mm x 423 mm 64g/m to 128g/m
2 2
DUPRINTER DP-21L
DUPRINTER DP-21S
Min. 100 mm x 148 mm
297 mm x 432 mm Max. 250 x 355 mm Max. 210 x 355 mm Max. 204 x 288 mm 1300 sheets (64g/m2, duodecimo 55kg, high grade paper) 900 sheets (64g/m2, duodecimo 55kg, high grade paper) *Cabinet [Option] : 1300 sheets ( 64g/m2, duodecimo 55kg, high grade paper) Max. 297 mm x 432 mm Min. 100 mm x 150 mm 53g/m2 to 210g/m2 (45kg to 180kg) Postcard (multifeeder only) 128g/m2 120 pages par minute.(60 to 120 pages par minute, 3 step adjustment) Max. 291 mm x 382 mm Min. 100 mm x 150 mm
Print enlargement/reduction Same size 100% Fixed zoom ratios 70, 81, 86, 115, 122, 141% A, B size model Print with border 94% Inch size model Same size 100% Fixed zoom ratios 64, 74, 77, Print with border 94%
Printing position adjustment Vertical 15 mm Holizontal 10 mm (Paper with the size of 297 mm x 420 mm or more : 5mm) Image mode Contrast control Ink supply method Color printing Master feeder Plate ejection Plate ejection capacity Plate ejection method LCD panel Other standard function Text mode / Photograph mode / Text and photograph mode Platemaking density 3 step adjustment Complete automatic control Drum unit exchange method Roll master automatic feed Complete automatic ejection plate rolling method 50 sheets Fan and paper ejection belt Light and compact type LCD OK monitor Confidential Safeguard Function Entry of different number of prints or sets Special function Memory functions 2 in 1 layout mode
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x Specifications
Specifications
Product name/model No. Power source 120VAC model 230VAC model Power consumption Size Operational Idle Weigft Operating temperature DUPRINTER DP-23S 120VAC 60Hz, 0.1A 230VAC 50Hz, 0.2A 190W(during platemaking), 85W(during 3rd -speed printing), 15W(during standby) When in use: 1270 (W) 9 673 (D) 9 680 (H) mm When folded away: 680 (W)9673 (D)9680 (H) mm Machine 68kg 10Y430Y DUPRINTER DP-21L DUPRINTER DP-21S
Option specifications
DUPRINTER DP-23S / DP-21L / DP-21S Options Drum unit KEYCARD COUNTER 4(built-in type) TAPE CLUSTER 4 PC interface kit The printer driver must be installed in the PC. Compatible with Windows95/98 Macintosh compatibility (System 7.6.1 or later, MAC OS or later) I/F board in main unit (on-line set III board unit)
PC interface kit
* Specifications are subject to change without notice.
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c Dimensions
cDimensions
105
472
617
705
517
229
563 1262
132
380
470
478
(mm)
23S0202
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v Mechanism
vMechanism
The machine carries out the processes of platemaking and printing. Platemaking In the platemaking process, the old master on the drum is removed while the thermal head creates the scanned image on the new master and transfers it onto the drum.
Master roll
Master ejection box
Thermal head
Drum unit
Printing In the printing process, paper separated from the stack by the paper feed roller and the paper separator unit is pressed against the drum unit by the press roller. There are small holes over only the image area of the master that is attached to the drum, and ink that seeps from these holes is transferred to the paper. The paper is then peeled from the master by the paper stripper finger. The paper is directed onto the paper ejection belt by a fan unit and discharged from the machine.
Drum unit Feeder roller Paper Paper stripper finger Ink
Press roller Paper sepatator unit
Paper ejection belt Fan unit
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b Master
bMaster
1. Characteristics of the master
(1) Structure of the thermal master
(2) Functions and materials of the layers Coated surface Prevents the film from fusing, being damaged due to friction,being peeled, and being conveyed defectively due to electric static charge. Material: silicon fluorine mold lubricant Thermal film Holes are made by the heat of the thermal head. Material: Polyethylene terephthalate (polyester) Adhesive 1] Adheres the film to the base. 2] Does not prevent ink from seeping. 3] Increases impression endurance. Base 1] Base material for the master. Fibrous layer 2] Ink seeps the base. (3) Cross section of the master during platemaking Holes are made on the coated surface, thermal film and adhesive, while base fiber, base material for the master, is left. A part of the film fused by the thermal head is stuck to the head or banks up.
(4) Printed image As the image consists of innumerable dots, it is taken as a continuous line through our eye. IMPORTANT : Precautions to be taken in dealing in the master. (1) Do not put a heavy thing on the box in which masters are packed. This may damage the master and may cause defective platemaking. (2) Do not leave the master as it is after it is taken out. Foreign objects are stuck to the master and this may cause defective platemaking. (3) Keep the master from direct sunlight, too high or low temperature and too high or low humidity. (Desirable storage temperature and humidity: 5-35 C, 20-80%) If the master curls, defective plate attachment may occur.
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n Ink
nInk
1. Characteristics of ink
(1)Ink type Ink for the digital printer is an emulsion type. It has a water-in-oil type structure. Emulsion type
(2) 2 characteristics The surface active agent has 2 characteristics: hydrophilic group and lipophilic group in 1 molecule. Oil and water bond together by these 2 characteristics as shown in the figure.
(3) Temperature Ink viscosity is high at a low temperature and it is low at a high temperature. So when ink is used at a low temperature (10C or less), the amount of ink transferred to the paper is smaller and the print darkness is slightly lighter. When ink is used at a high temperature (30C or more), the amount of ink transferred to the paper is larger and the print darkness is slightly darker. IMPORTANT : Precautions to be taken in handling ink (1) Storage environment When an emulsion type ink is stored at too high or low temperature for a long time, oil and water in the ink pack may be isolated. Keep the ink from too high or low temperature (5C or less, 35C or more). Also keep the ink from direct sunlight since the temperature rises sharply in the direct sunlight. When the water content is frozen, the water content is solidified and the bond characteristics decreases. When ink is stored at a high temperature, the bond characteristics decreases due to the change of the surface conditions (surface tension, solubility). The bond characteristics also decreases due to evaporatin of the water content. (2) Precautions to be taken in handling the ink pack When the ink pack is removed from the drum unit to store, put the ink pack with its mouth up, screw the cap firmly after expelling air from the ink tube. (If air is in the ink pack, water content is generated.) 19
chap.1
m System Setup
mSystem Setup
The machine and its optional equipment are set up as follows:
Duplo Direct Print System
KEYCARD COUNTER 4 TAPE CLUSTER 4
Personal computer
Cabinet (Printer stand)
Drum unit
: Option
NOTE :
DDP system Documents prepared on a personal computer can be printed on this machine. The PC interface kit is required to connect this machine to a personal computer.
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chap.1
, Part Names and Their Functions
,Part Names and Their Functions

1. Machine exteriors
Document tray Document receiving tray (Top cover) Document guides ADF
LCD Feed tray descend switch Control panel Feed pressure adjuster lever Slide guides Front cover Feed tray Supplemental paper tray
Power switch
Cabinet (Printer stand) Caster locks
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Master set lever
Master roll
Document receiving tray (Top cover)
Master cover release lever
Master cover
Ink pack holder release lever
Front cover
Drum handle
Drum unit
Ink pack
Drum securing lever
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Master ejection core
Master ejection box release lever
Master ejection box lid release lever Master ejection box
Paper stacker guides
JOG switch (Drum rotator switch)
Paper stopper
Print tray
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2. Sectional (structural) view of the machine

No. 1 2 2A 2B 2C 3 4 Section Name Scanner section Platemaking/Master feed/ejection section Platemaking/Master feed section Master ejection section Master clamp opening/closing section Paper feed section Drum driving section Press section Paper ejection section Print tray Drum section
Mechanism 127page 135page 135page 140page 142page 144page 148page 4 150page 4 153page
Srandard/Adjustment 162page 163page 163page 164page 166page 171page 176page 178page 180page 4 182page
56page 64page 64page 76page 78page 84page 97page 103page 106page 4 111page
2A
2C
6 7 8
2B 4,8 3
2B 4,8
6 7
23S0201
24
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3. Control Panel
1. Keys outside of the panel cover r LCD panel
a see page 28
1:1
1 4
2 5 8 0
3 6 9
X =
STD
STD
7 C
!7
!6
!5
!4
!3
!2
!1
!0
No. q w
Name OK monitor
Function
No. i
Name STOP key
Function Press to stop printing on the way. If this key is pressed while the machine is stopped, the total number of prints and plates will be displayed on the LCD panel. Starts printing. This will not start platemaking. Platemaking will start automatically after the end of printing if there is a document on the ADF. Returns the control panel settings to the Standard Mode settings. Press and hold for at least 0.5 seconds. Press to enter the number of prints and number of sets for sectional prints. Use to enter the number of prints. Press to reset the displayed number of prints to 0. Only the number of prints is cleared. The lamp of the specified printing speed lights. Press to adjust the printing speed. Press to adjust the printing position. The lamp of the specified printing speed lights. 27
r t
y u
Flashes to display the content of the trouble and lights to indicated the part that caused the trouble in the machine. ENLARGEMENT key Press to set the enlargement ratio. 100% key Press to reset the ration to 100%. REDUCTION key Press to set the reduction ratio. 100% lamp Lights when the 100% ratio is selected. DOCUMENT MODE Press to switch between the text mode, text/photograph mode and photograph mode. Each press of this key moves the position of the lit SWITCH key lamp that indicates the selected document mode. Document mode indicator lamps The lamp of the selected mode lights. LCD panel Displays the number of printed paper. Also displays an error message when an error occurs. FUNCTION SWITCH key Press to toggle between the normal mode and the function select mode. SELECT key Press to select a function. TEST PRINT key Press to print only one piece of paper for checking the print darkness or printed position. PLATEMAKING key Press to start platemaking.
PRINT key
!0
ALL CLEAR key
!1 !2 !3 !4 !5 !6 !7
key
Key pad CLEAR key Printing speed indicator lamp PRINTING SPEED ADJUSTMENT key PRINTING POSITION ADJUSTMENT keys Printing position indicator lamp
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2. LCD Panel
0sht
q
1set
w
No. q w
Name Print count Sets
Function Displays the number of prints to be made. Displays the number of sets to be printed.
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. Operation Procedures
.Operation Procedures
1. Printing
Set document
Function switch Select key key Reduction is selected. Document size is selected. Photograph mode is selected. Plate darkness is switched. Document mode switch key Selects Texts, Text/Photograph & Photograph mode. When the number of prints is input in advance, printing starts automatically after platemaking. / / keys keys Printing position is adjusted. Printing speed is adjusted. Printing is tested (a sheet of paper.)
Platemaking
key
Printing position adjustment Printing speed adjustment Test print key
Input the number of prints and the number of sets
Input the number of prints and the number of sets on the key pad.
Print
key
End
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0 Error Messages and Corrective Action
0Error Messages and Corrective Action

1. Error messages
The LCD displays a message when the replenishment of consumables or the assistance of service personnel is required.
Message
EXCHANGE INK
Cause and corrective action

Cause : There is no ink. Action : Replace the old ink pack with a new one.
See page
32
ROLL - MASTER END
Cause : There is no master. Action : Replace the master roll with a new one.
34
EXCHG. EJECT - CORE
Cause : The master ejection core is full. Action : Replace the core with a new one.
37
SET PRINT PAPER
Cause : There is no paper in the feed tray. Action : Load the feed tray with printing paper.
39
DRUM NOT SET
Cause : There is no drum. Action : Install a drum in the machine.
43
FRONT COVER OPEN
Cause : The front cover is open. Action : Close the front cover.
SCANNER OPEN
Cause : The ADF cover is open. Action : Close the ADF cover.
DOC. TRAY OPEN
Cause : The document receiving tray is open. Action : Close the document receiving tray.
PAPER LEFT JAM
Cause : A paper jam has occurred on the ejection side. Action : Inspect the ejection side and remove the jammed paper.
45
PAPER RIGHT JAM
Cause : A paper jam has occurred on the ejection side. Action : Inspect the ejection side and remove the jammed paper.
46
MAST. COVER OPEN
Cause : Master roll cover is open. Action : Close the cover.
RESET MAST. ROLL
Cause : The master roll is not set correctly. Action : Reset is correctly.
51
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Message
MAST. EJECT ERROR
Cause and corrective action

Cause : There is an old master on the drum. Action : Remove all the masters from the drum.
See page
49
MASTER SET MISS
Cause : There is an error during master setting. Action : Open the top cover and remove the master that is left in the plate feeder. Cause : The document is jammed on the ADF. Action : Open the ADF cover and remove the jammed document.
51
DOCUMENT JAM
PLEASE WAIT
Cause : The printer is not ready. Action : Please wait with the power ON. If the message remains after a few minutes, turn the power OFF and ON again. If the message still remains after a few minutes, turn the power OFF and contact your service person. 4
SET KEYCARD
Action : Insert the key card into the KEYCARD COUNTER. 4
PLS PLATE MAKING
Cause : Cannot print. Action : This message is displayed if you press (PRINT) or (TEST PRINT) keys without making a plate immediately after a master setting error or when the confidential safeguard function is ON.
T
PRINTING
Cause : Printing is not complete. Action : Either press (PRINT) key to resume printing or press C (CLEAR) key to clear the counter.
SERVICE CALL ( "E***" flashes )
Action : Follow the procedure below. qRecord the error message "E***". w Shut off the power and turn it back on. eIf the message is displayed again, contact service personnel. Report the error code and details of error occurrence to service personnel.
228
* For displayed messages other than those listed above, refer to Chapter 7 "Troubleshooting". a See page 212
31
chap.1
2. Corrective action
(1) Replacing the Ink Pack
IMPORTANT : Only use ink packs designed for this machine.

Open the front cover.

Master roll Master ejection box
Thermal head
Drum unit
Grasp the lever and pull it toward you.
Lever
Ink pack

Lift out the empty ink pack.
Ink pack
Remove the cap from a new ink pack.

IMPORTANT : Do not leave an ink pack uncapped for longer than necessary.
32
chap.1

Insert the ink pack so that the groove on the lip fits onto the U groove of the holder.
"U" groove of holder

Push the ink pack in to the set line on the ink pack.
Set line
Set line
Press the back of the holder in with the palm of your hand.
Close the front cover.
Front cover
33
chap.1
(2) Replacing the Master Roll
IMPORTANT : Only use a master roll designed for use in this machine.

Open the document receiving tray.
Document receiving tray
Press the master cover release lever. The master cover will open up.
Master cover release lever
Master roll Master cover
Lift out the master roll.
Take out a new master roll from the bag.

34
chap.1

Insert the master roll into the machine so that the green line on the roll is facing the control panel.
Pay attention to orientation Master roll
23S0002

Peel off the seal.
Green line
Seal

23S0003
Bar Warning label 1
Pull out the master, and pass it under the bar.

WARNING Do not remove the cover with Warning Label 1. You may be injured by the movable cutter inside the machine.
23S0005
Set line
Push in the master, aligned with the setline, until the master's leading edge contacts the interior surface.
23S0006
35
chap.1

Close the master cover.
Master cover
23S0007
Push the master set lever.protruding from the

The master is pulled in. IMPORTANT : If the master is not pulld in open the master cover, and gently press in as far as possible to set again.
Master set lever
23S0008
Make sure that the leading edge of the master is protruding from the inner side of the master cover.
IMPORTANT : If the master cannot be set correctly, its leading edge will not be visible. Open the master cover, and set again.
Gently close the document receiving tray.
36
chap.1
(3) Replacing the Master Ejection Core
IMPORTANT : Use only a master ejection core designed for use in this machine.

Press the master ejection box release lever to open the master ejection box.
Open the master ejection box until it stops.
Open the cover while pressing and holding the lid release lever.
Master ejection box lid release lever
Holding the edges of the master ejection core, pull out the core and discard it.
IMPORTANT : Ink adheres to the master ejection core. Take care to prevent ink from getting onto your clothing.
37
chap.1

Insert a new master ejection core.

Gently close the master ejection box cover, pressing it until it locks.
Master roll Master ejection box
Thermal head
Drum unit
Close the master ejection box, pressing it until it locks.
38
chap.1
(4) Supplying Paper Supplying Paper

Open the supplemental paper tray if it is closed.
Hold the lever and adjust the side guides to the paper size.
Load a stack of aligned sheets between the paper guides and press the stack lightly toward the machine.
IMPORTANT : You can load the feed tray with approximately 1,300 sheets of 55gsm high-grade paper.
39
chap.1
Changing Paper Selection

Press
(STOP) key.
Printing stops.
Press the feed tray descend switch continuously. Release the switch when the feed tray is at the proper height.
The feed tray will stop.
Feed tray descend switch
IMPORTANT : If the sheet is still in the paper feed roller, pull it out and align it with the stack.
Remove paper from the feed tray.

The feed tray will automatically descend.
40
chap.1
When the feed tray comes to a syop, reset the paper size.
Press
(PRINT) key.
The feed tray will rise automatically and printing will resume.
If Paper Runs Out During Printing

If paper runs out during printing, printing stops and the feed tray is lowered automatically. a See page 39

Adding Paper While Printing

Press
(STOP) key.
Printing stops.
Press the feed tray descend switch continuously. Release the switch when the feed tray reaches the proper height.
The feed tray will stop.
41
chap.1
IMPORTANT : If the sheet is still in the feed roller ring, pull it out and align it with the stack.
Align the stack to be added and place it on top of the existing stack. Press the stack lightly toward the machine.
Press
(PRINT) key.
The feed tray will rise automatically and printing will resume. NOTE : When you press stops.
(STOP) key, printing
42
chap.1
(5) Replacing the Drum Unit

Press and hold the JOG switch until the drum comes to a stop with a beep.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.
Open the front cover toward you.
Front cover
Lift the drum securing lever toward you and, holding it there, then pull out the drum handle straight toward you until it stops.
Drum handle
Drum securing lever
Hold the handle on the far end of the drum, and lift the front end of the drum slightly to pull the drum toward you.
IMPORTANT : Do not touch the drum surface. Ink may transfer to your clothes. Hold the drum level and place it on a flat, solid surface.
Handle for end of clrum
43
chap.1
Installing the Drum Unit

Hold the drum level and place the drum guide roller onto the rail in the machine.
Roller
Rail

Release the handle at the far end of the drum and press the drum in about 10cm while lifting up the front end slightly.
Hold the drum level and press it in gently until it comes to a stop.

Lift the drum securing lever toward you while pressing the drum in.
Lever
Lower the lever.
Lever
Close the front cover.

44
chap.1
(6) Paper Jam (Feeder Side)
If the message "PAPER LEFT JAM" is indicated in the LCD, check the feeder side and remove the jammed paper by following the procedure below.
PAPER LEFT JAM
Switch to lower the feed tray slightly. The feed tray is lowered for the time that the switch is pressed.
Pull out the jammed paper as shown in the diagram.
Press and hold the JOG switch until the drum comes to a stop with a beep.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.
45
chap.1
(7) Paper Jam (Ejection Side)
If the message "PAPER RIGHT JAM" is indicated in the LCD, check the ejection side and remove the jammed paper by following the procedure below.
PAPER RIGHT JAM
Press the master ejection box relase lever to open the master ejection box.
Remove the jammed paper.

Press the JOG switch to eject the partially printed paper. WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands or fingers inside the machine while it is operating. Your hands may be pulled in or nipped.

46
chap.1
Paper Adhering to Drum

Press the master ejection box relase lever to open the master ejection box.
Press the JOG switch to find the edge of the paper, then stop the drum at the position shown in the diagram.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands inside the machine while it is operating. Your hands may be pulled in or nipped.
Paper edge
Peel off the edge of the paper from the drum.
47
chap.1

Pull the paper toward the ejection side while pressing the JOG switch to peel the paper off.
IMPORTANT : Make sure that the peeled paper does not stick to your clothing.
Hold the JOG switch down until the drum comes to a stop with a beep.


Make another plate.

48
chap.1
(8) Master is Not Ejected

Press the master ejection box release lever to open the master ejection box.
Press the JOG switch to find the edge of the paper, then stop the drum at the position shown in the diagram.
WARNING Do not touch the drum or rollers when you operate the JOG switch. Do not put your hands inside the machine while it is operating. Your hands may be pulled in or nipped.
Lift the lever toward you.

The master clump opens and the edge of the master will be released from the clump. If the master is stuck, release it manually.
Master clump Lever Master
49
chap.1

Return the lever.

Pull the front end of the master toward you and press the JOG switch intermittently.
Hold the switch down until the master peels off. IMPORTANT : Discard the old master, making sure that it does not touch your clothing.
Hold the JOG switch down until the drum comes to a stop with a beep.


Press
(STOP) key.
The message is deleted.
Make another plate.

50
chap.1
(9) Master Set Incorrectly("MASTER SET MISS" is displayed)

Open the document receiving tray.
Remove the master left in the master feeder.

Set the master roll.
Gently close the document receiving tray.
Check that the error message is deleted.

Make a new plate and start printing.

IMPORTANT : The message PLS PLATE MAKING is displayed on the LCD panel when is pressed without platemaking being carried out.
(PRINT) key
51
chap.1 1Option
1Option
1. DUPRINTER Option
(1) TAPE CLUSTER 4
Open out the tape cluster body.
Tape cluster body
23S0029
Remove the old tape core.

Install the new tape. Make sure it will wind off in the correct direction.
Lever

43SH0104
Lift up the lever and pass the tape through the slot.
Tape
23S0030
Make about 1cm of tape protrude out of the slot.
1cm
23S0031
Swing the tape cluster body back in.

52
chap.1 1Option
MEMO
53
Chapter 2

Master Clump opening/Closing Section ................78 1. Description...............................................................78 2. Operation of Master Clump Open / Close Lever ........79 (1) Structure.............................................................79 (2) Plate Attachment / Detachment Operation ......80 (3) Clump Opening / Closing Lever Position (A / B / C Mode) .........................81 3. Function of Parts ....................................................82 (1) A / B / C Mode Sensor.........................................82 4. Returning Operation Flowchart When the Power is Cut Off Accidentally ...............83 c Paper Feed Section......................................................84 1. Description...............................................................84 2. Operation .................................................................85 (1) Rotation of the Paper Feed Roller and Timing Roller .....................................................85 (2) Paper Feed Roller Drive.....................................86 (3) Driving of the Timing Roller..............................87 (4) Escape the Guide Roller DP-21S/L ............................................................88 DP-23S................................................................89 (5) Paper Feed Length .............................................90 3. Function of Parts .....................................................91 (1) Printing Position Adjustment Mechanism........91 (2) Signal Lever........................................................93 (3) Feed Tray (Elevator) Upper Limit Sensor ........94 (4) Feed Tray (Elevator) Lower Limit Sensor ........95 (5) Paper Sensor.......................................................96
z Scanner Section...........................................................56 1. Description...............................................................56 2. Sequence of Operation ...........................................57 (1) Document detection............................................57 (2) Basic Operation for Feeding Paper to Scanner.58 (3) Operation on Continuous Platemaking ............59 3. Function of Parts and Circuit .................................60 (1) Document Sensors..............................................60 (2) CCD / Lamps ......................................................61 (3) Scanner Stepping Motor / Clutch A, B ..............62 (4) ADF Cover(Scanner Cover) Open / Close Detection .......................................63 x Platemaking / Master Feed / Ejection Section...........64 Platemaking / Master Feed Section ........................64 1. Description...............................................................64 2. Sequence of Operation ...........................................65 (1) Operation when the master set switch is turned on.............................................65 (2) Platemaking / Master Feeding ..........................66 3. Function of Parts ....................................................67 (1) Thermal Head.....................................................67 (2) End Mark Sensor ...............................................70 1. Master Setting Error Detection ......................71 2. Master End Detection......................................71 (3) Master Position Sensor ......................................72 (4) Cutter Unit.........................................................73 (5) Master Feed Clutch (Electromagnetic clutch) ..74 (6) Document Receiving Tray Open / Close Detection.......................................75 Master Ejection Section ...........................................76 1. Description...............................................................76 2. Circuit .......................................................................76 3. Function of Parts ....................................................77 (1) Master Ejection Sensor ......................................77 1. Plate Ejection Error Detection........................77 2. Rotation Control of the Roll-up Motor............77
54
v Drum Driving Section ..................................................97 1. Description...............................................................97 2. Function of Parts ....................................................98 (1) Home Position / Jam Detection Position Sensor ..................................................98 (2) Master Attachment / Detachment Position Sensor ..................................................99 (3) Jog Switch(Drum Rotator Switch)...................100 (4) Control of the Main Motor ...............................101 1. Rotation Speed Control by Encoder Sensor .102 2. Selecting the Speed........................................102 b Press Section .............................................................103 1. Description.............................................................103 (1) Press Roller Timing & Printing Area..............103 2. Function of Parts ..................................................105 (1) Press Roller (P Roll) Sensor.............................105 n Paper Ejection Section ..............................................106 1. Description.............................................................106 2. Function of Parts ..................................................107 (1) Paper Stripper Finger ......................................107 (2) Jam Sensor ......................................................108 1. Paper Jam Detection Timing ........................109 (3) Paper aligning mechanism ..............................110
m Drum Section .............................................................111 1. Description.............................................................111 2. Circuit .....................................................................112 3. Function of Parts ..................................................113 (1) Ink Detection ....................................................113 1. LED Display and Output Signal on the Ink Detection PCB Unit..........................114 2. "CHANGE INK" Display Timing ..................115 (2) Ink Pump ..........................................................116 (3) Drum Switch.....................................................117 (4) Front Cover Open / Close Detection Switch....118 , Option .........................................................................119 (1) TAPE CLUSTER ..............................................119
55
chap.2
z Scanner Section
zScanner Section
1. Description
The machine contains a scanner of the document moving type which scans images while the document is fed.The document is illuminated with the lamps while being transferred, and the reflection in proportion to the document image darkness is imaged on the CCDs through the mirror and lens. Then the image is resoluted into picture elements and converted photoelectrically into the level of electricity simultaneously. The document is fed and carried by a single stepping motor. Two clutches (A and B) are used to engage or disengage the ADF feed roller and the feed roller.The clutch is turned on only for feeding paper to engage the scanner stepping motor with the driving system for the ADF feed roller.After the document reaches the feed roller, clutch A is turned off and clutch B is turned on.The roller follows the movement of the document (fed by the ejection roller).
Document sensor Clutch A ADF feed roller
ADF paper separator unit Feed roller Document position sensor Glass Clutch B Scanner JAM sensor Shading plate Ejection roller Roller Lamp
Mirror
Ejection roller
Roller
Mirror
Lens
CCD
23S0203
56
chap.2
z Scanner Section
2. Sequence of Operation
(1) Document detection 1.Detection of the the document 2.Detection of the front end of the document 3.Detection of the rear end of the document 4.Detection of the finish of the document (1) Detection of the document
The document sensor detects the document on the document receiving tray.When the document is placed on the document receiving tray, the document sensor is photointerrupted and detects the presence of the document, which turns on the scanner stepping motor and the clutch A to feed paper.
(2) Detection of the front end of the document

The document position sensor detects the front end of the document before the reading section. When the document position sensor is photointerrupted by the document fed with the ADF feed roller, it detects the front end of the document.
(3) Detection of the rear end of the document

The document position sensor also detects the rear end of the document during platemaking.When the document is fed 20 mm after the rear end is detected, the reading of the document is finished and the scanner stepping motor runs at a slower speed than the document reading speed to eject the document.When the document is fed approx.20 mm after the reading is finished, the scanner stepping motor stops.
IMPORTANT : The reading of document is terminated at the earlier time when the longitudinal length is
fed of the document size selected on the control panel or the document is fed approx.20 mm after the rear end is detected.If platemaking for the document with an unspecified size is required, select a document size on the control panel with a longer longitudinal length than the longitudinal length of the document.
(4) Detection of the finish of the document

The document sensor also detects the finish of the document on the document receiving tray.When the rear end of the last document on the document receiving tray have passed by the document sensor, the sensor is photoexposed and detects the finish of the document, which prohibits feeding the next document.
57
chap.2
z Scanner Section
(2) Basic Operation for Feeding Paper to Scanner Operation

(1) Paper feed 1 When the document is placed on the document receiving tray, the document sensor is photointerrupted and detects the presence of the document. Pressing the PLATEMAKING key turns on the scanner stepping motor and clutch A, feeding the document. 2Paper feed 1
Document Document sensor
23S0204
(2) Positioning Clutch A and the stepping motor are turned off when the document is fed 16mm after the JAM sensor is photointerrupted. This prevents the position of the documents from deviating, which is caused by meandering during paper feeding. If the front end of the document does not reach the document sensor within 5 seconds after the JAM sensor is photointerrupted, DOCUMENT JAM will be displayed.
2Positioning
Scanner JAM sensor Document position sensor (Photo interrupting)

23S0206
(3) Paper feed 2 The scanner stepping motor and clutch B are turned on again and the document is fed.
(4) Reading the document After the front end of the document is detected at the document sensor, the document is fed several steps, and shading is performed on approximately 2mm of the front end of the document.
2Reading the document
Glass Ejection roller Lamp

23S0207
58
chap.2
z Scanner Section
(3) Operation on Continuous Platemaking Operation

(1) Paper feed 1 for the second document If the document sensor is photointerrupted when the document has been ejected and platemaking process is finished at the master feeding section, it is determined that the next document exists and the scanner stepping motor, and the clutch A is turned on to feed the document.
2nd document Document sensor
1st document
23S0211
(2) Positioning When the front end of the document reaches the document position sensor, the document position sensor is photointerrupted and detects the front end of the document, which turns off the scanner stepping motor and the clutch A to hold.This method assures stable positioning of the document.
2nd document
Document position sensor

23S0212
(3) Reading the document After the front end of the document is detected at the document sensor, the document is fed several steps, and shading is performed on approximately 2mm of the front end of the document.
IMPORTANT : When PLATEMAKING
2nd document
Glass
key is pressed, the print section detaches the plate and then the drum moves to the plate attachment position to open the master clamp, while ADF remains held.
Lamp
23S0213
59
chap.2
z Scanner Section
3. Function of Parts and Circuit

(1) Document Sensors Description
The document sensors detect the five types of document detection. 1.Detection of the document 2.Detection of the front end of the document 3.Detection of the rear end of the document 4.Detection of the finish of the document 5.Detection of document jam
Circuit
Document sensor 1 2 3 Red Yellow Blue CN5-1 -2 -3 5V Red Orange Blue CN5-4 -5 -6 5V Red Yellow Blue CN4-1 -2 -3 5V 5V
Main P C B U nit
5V Photo passing:0V Photointerrupting:5V
Scanner JAM sensor 1 2 3
5V 5V Photo passing:0V Photointerrupting:5V
Document position sensor 1 2 3
5V 5V Photo passing:0V Photointerrupting:5V
23S0319E
Operation
Document sensor
Scanner JAM sensor
23S0214
60
chap.2
z Scanner Section
(2) CCD / Lamp Description

The lamp illuminates the document and the reflected light is transmitted onto the CCDs.The CCDs output the image signals in level of voltage.
Circuit
Specification
CCD The table below shows the specification for the CCD.
No. 1 2 3 4 5
Item Optical signal storage time (SH cycle) Frequency The number of effective picture elements Reading width (This is not the image width which can be processed.) Reading density
Specification 2.048 msec/line 3.375MHz 3000 picture elements 254mm 11.8 dot/mm(300DPI)
Lamp This machine adopts a xenon lamp which is lit quickly when turned on, and the quantity of light is stable.The lamp is lit when the the control signal CN1-1 for the lamp inverter unit is LOW (0V) .
61
chap.2
z Scanner Section
(3) Scanner Stepping Motor/Clutch A, B Circuit

D r ive P C B U nit Scanner stepping motor 1 2 3 4 5 6 Black Light green Pink Blue Yellow White CN5-4 -5 -6 -7 -8 -9
Clutch A
Black Black
1 2
Brown Purple
-10 -11
Clutch B
Black Black
1 3
Brown Light blue
-12 -13
23S0325E
Operation
The rollers for ADF are driven by the scanner stepping motor (PM1) .The paper feed roller is engaged with the drive system when the scanner clutch (CL1) is turned on.
62
chap.2
z Scanner Section
(4)ADF Cover (Scanner Cover) Open / Close Detection Description

Opening and closing of the ADF cover (scanner cover) is sensed by a microswitch. If this cover has not been completely closed, SCANNER OPEN will be displayed.
Circuit
ADF cover switch 5V Yellow Yellow 1 Yellow 3 Yellow CN3-1 -3 5V 0
Main P C B U nit
23S0311E
Operation
When the ADF cover (scanner cover) is closed, the switchs actuator is pressed down and the switch is OPEN. When the cover is opened, the actuator is released and the switch is CLOSED. 2When the ADF cover is closed 2When the ADF cover is opened
ADF cover
ADF cover
Actuator is pressed
Actuator is released
23S0292
63
chap.2
x Platemaking / Master Feed / Ejection Section
xPlatemaking / Master Feed / Ejection Section

See page 78
Platemaking / Master Feed section Master Clump Opening / Closing Section
See page 76
Master Ejection Section
63S00207
Platemaking / Master Feed Section
1. Description
Make the master clump of the drum unit clump the master top end, performing platemaking on the master with the thermal head. (In this machine, the master on the drum is ejected at the same time when platemaking is performed.) The master is conveyed to the drum unit via the platen roller and sponge roller by driving of the stepping motor, while it is being processed in the head section. Sponge roller is driven through the master feeding clutch (electromagnetic clutch), and controls the amount of master conveyed to the master clamp section of the drum unit with the master feeding clutch ON / OFF. The end mark sensor starts to detect when the end mark (black) section printed on the end of the roll master is conveyed. "ROLL MASTER END" is displayed on the error display panel. The endmark sensor also detects whether the master is conveyed properly through the sensor.
Master feeding clutch Cutter unit
Sponge roller Drum unit
Master position sensor
Platen roller
Master cover switch Roll master Thermal head End mark sensor Stepping motor
23S0273
64
chap.2
2. Sequence of Operation
(1) Operation when the master set switch is turned on
When the master set lever is switched on, the platen roller and sponge roller rotate and feed out the document for 10 seconds.
Master Master set lever
Sponge roller Platen roller
Switch ON
23S0217
When the master position sensor is interrupted, the master is fed a few steps and stopped.
Photo passing / Photo interrupting

23S0218
HELP mode H-29 \ see p.268
65
chap.2
(2) Platemaking / Master Feeding Operation

When platemaking operation starts, the drum unit rotates to perform plate detachment process. The drum which has finished plate detachment process stops at the plate attachment position.
63S00211
Open the master clump. Sponge roller rotates with the master feeding clutch ON. A certain amount of the master tip end is fed to the master clump section and the sponge roller stops.
Master feeding clutch Sponge roller Master tip end
63S00212
Open the master clump

Master clump
63S00213
After the master clump is closed and clump the master tip end, the drum rotates to roll up the master. *Check the length of the master and drum rotation angle to control the drum rotation. *As the electromagnetic clutch is OFF, the sponge roller is free. When the master bottom end reaches the top of the drum, plate attachment is completed. Commence printing.
Drum
63S00214
Cutter
63S00215
66
chap.2
3. Functions of Parts
(1)Thermal Head Description
The thermal elements are in alignment in the scanning direction, and are heated on the image section to make holes on the master film.
Circuit
Drive PCB unit CN6-1
-14 Thermal head
Drive PCB unit CN3-1
-24
23S0320
Specifications
No. 1 2 Item Picture element density Effective memory width DP-23S/DP-21S/DP-21L 300DPI (11.8 dot/mm) 260.2 0.1mm
67
chap.2
Exterior and Lot No.
276.0 260.16 0.1
0.2 Thermal resistor line
Thermistor
Label
Model name Power connector
Lot No.
Resistance Signal connector
Pin (No.1)
Pin (No.1)
23S0221
NOTE :
Lot No.
Lot No. is shown with 4 digits including alphabet. Each digit has the following meanings. Serial No. in the production month Production month (See the table) Production year
Lot No.
Serial No. Serial No. in the production month Production month (See the table) Production year (Year of decade)
23S0222
Sign
Month Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.
68
chap.2
NOTE :
Resistance
Resistance value is described on the label. When the head is replaced and the HELP mode is initialized, set the DIP-SW (H-44) of the HELP mode. HELP mode H-44 \ see p.280
Resistance value ( 3825 3909 3994 4078 4163 4247 4331 Resistance value
23S0326
H-44 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
3908 3993 4077 4162 4246 4330 4415 4499 4583 4668 4752 4837 4921 5005 5090 5175
4416 4500 4584 4669 4753 4838 4922 5006 5091
69
chap.2
(2) End Mark Sensor

Description The end marks are located at a fixed distance relative to the master; as the master is being fed, the end mark sensor senses master condition and the end marks by means of intensity of reflected light.
End mark sensor
End mark
23S0219
Reflection light amount The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 13. HELP mode H-13 \ see p.252
2Value of the HELP mode H-13

Black level maximum
* Adjustment of end mark PCB unit Adjust the HELP mode H-13 so the difference between the maximum value of the black level and the white level becomes a maximum. HELP mode H-13 \ see p.252
White level 5 Black level maximum -10
Circuit
5V
VR1
5V CN1-1 -3 Blue Red 1 Blue CN2-4 -5 -6
5V 5V 0
-2 Light green
2 Light green 3 Red
Main P C B U nit
End mark sensor PCB unit
23S0327E
70
chap.2
1. Master Setting Error Detection

Operation In platemaking, the end mark sensor uses amount of reflected light to detect presence or absence of a master on the transfer path. Then the following displays and operations are performed: 2When a master setting error is detected, "MASTER SET MISS" is displayed and printing is not processed. 2"MASTER SET MISS" is only cleared by opening and closing the top cover. (It is not cleared by turning the power off.) 2Printing is not performed but platemaking is only performed when the display is cleared after "MASTER SET MISS" is displayed. (Because the master is not attached to the drum.)
Timing (1) While platemaking is being processed, the reflection light amount does not turn to be in a white level. (2) When platemaking process is finished (before printing process), the reflection light amount is in a white level.
2. Master End Detection

Operation The end mark is printed on the area about 1 m from the end of the master. 2When the end mark is detected, "ROLL-MASTER END" is displayed. 2When "ROLL-MASTER END" is displayed, plate-making is not performed next. Timing When it is considered that the end mark is read under the following conditions, "ROLL-MASTER END" is displayed. q While the master is rolling up to the drum during platemaking, the following is checked. w When the master passes under the end mark sensor, the amount of reflected light is read. e If the following conditions are met, it is considered as master end. Maximum Minimum 10 and Maximum white level top limit
HELP 13 Display value 63 Smaller MAX Black level top limit Reflection light amount
MIN
White level top limit Black level maximun 10 Larger 00
71
chap.2
(3) Master Position Sensor Description

The master position sensor is located at a fixed distance relative to the master. By means of reflected light, this sensor senses the presence of the master on the master travel path, and controls its attachment position. If the intensity of the reflected light does not reach the "white" level (which indicates presence of the master) a single time during platemaking, "RESET MAST. ROLL" is displayed.
Master

23S0220
Reflection light amount The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 13. HELP mode H-13 \ see p.252
Circuit
Master position sensor 5V 1 2 3 Red Green Blue 5 Red CN2-28 -29 -30 0 5V Photopass : 0V Photointerrupting : 5V 5V
6 Green 7 Blue
Main P C B U nit
23S0328E
72
chap.2
(4) Cutter Unit Description

Completed, the stepping motor for platemaking and the drum stops temporarily, the cutter motor is turned on to drive the cutter and the master is cut.
Circuit
Cutter motor (M5)
Black Red
1 2
Black Red
CN4-5 -6
Drive PCB unit CN1-1 -14 -32
Main PCB unit
CN1-19
23S0322E
73
chap.2
(5) Master Feeding Clutch(Electromagnetic clutch)

Description Sponge roller is attached to the bottom section of the master conveyance way of the master feeding unit, and is driven via the master feeding clutch (CL1) by the platemaking motor. The rotation of sponge roller is controlled with the master feeding clutch ON / OFF. Circuit
Master feeding clutch (CL1) Black White 1 Brown 2 White 1 Brown 2 White 24V CN4-3 -4 Drive PCB unit CN1-1 -14 -32
Main PCB unit

23S0323E
Operation 1) In the platemaking process, when the drum stops in the master winding position, the master feeding clutch comes on, so that sponge roller is driven and feeds out the master by a fixed amount.
CN1-19
Master feeding clutch Sponge roller
B mode
Master tip end
63S00217
2) The master clump opens and closes, to clump the master.
C mode
Master clump
63S00218
3) When the master is wound onto the drum, the master feed clutch turns off, leaving sponge roller free to be turned by the master as it is wound off the drum.
Drum
B mode
63S00219
74
chap.2
(6) Document Receiving Tray (Top Cover) Open / Close Detection Description
Opening and closing of the document receiving tray is detected by the document receiving tray open / close detection SW (MS3). This machine does not work (except for the master setting SW and the drum rotation SW) unless the tray is closed firmly. The machine stops immediately when the tray is open. (after finishing platemaking if platemaking is being performed.)If the document receiving tray open is detected."DOC. TRAY OPEN" is displayed.
Circuit
Document receiving tray open / close switch (MS3) 5V Pink Pink CN2-14 -15 When the tray is closed : 0V When the tray open : 5V 5V 0
Main P C B U nit
23S0311E
Operation
When the document receiving tray is closed, the switch is pressed; OPEN. When the tray is open, the actuator is released; the switch is turned to CLOSE. 2When the document receiving tray is closed
Actuator is pressed
2When the document receiving tray is opened
Document receiving tray (Top cover) Connector switch Actuator is released
75
chap.2
1. Description
When the drum stops at the plate detachment position and the master clump which clumps the master tip end is opened (C mode), the pulling roller on the rolling section of the master ejection box pulls the master tip end into the box inside, and the master is rolled up to the core. If no core is installed, or when the master is fully wound onto the core, the core full switch (MS8) is mechanically actuated, and the message "EXCHG. EJECT-CORE" appears on the operation panel LCD panel.
Pulling roller
23S0311
Plate detachment position
Master ejection sensor photoemitting PCB
Master ejection box Core Master ejection sensor photo-receiving PCB JAM sensor photoemitting PCB
Core full switch Roll up motor

23S0264
2. Circuit
Black Rollup motor Brown Light 2 blue 1 Green Drive PCB unit 2 Light blue 1 Green CN4-13 -14
2 Jam sensor photo-receing PCB 1
Pink Blue
CN10-18 -19
1 Master ejection sensor photo-receing PCB 2
Blue Gray 5V 5V -1 -2
-20 -21
1 Core full switch 1 Master ejection sensor photo-emitting PCB 2 2 5 6
Orange Orange Blue Gray
-22 -23 5V
Jam sensor photo-emitting PCB
1 2
3 4
Blue Pink
-24 -25 5V Main PCB unit

23S0324E
76
chap.2
3. Function of Parts
(1) Master Ejection Sensor
Description Photo-emission from the master ejection sensor is received on the master ejection sensor, and the sensor detects with the photo strength whether the master is pulled to the master ejection box. Photo-receiving amount is checked with the HELP mode H-05 \ see p.244 HELP5. 2HELP mode H-05 value
63
00 Smaller Larger Photo-receiving amount
1. Master Ejection Error Detection

Operation While one platemaking is being processed, the difference of photo-receiving amount is less than 8 by checking with the HELP5, which is determined as an master ejection error. The following display and operation are shown. 2"MAST. EJECT ERROR" is displayed on the error display panel and printing is not processed. 2 "MAST. EJECT ERROR" is cleared with the ALL CLEAR key , STOP key or by performing platemaking / printing. 2A plate ejection error is not detected for one platemaking soon after a plate ejection error or master setting error is detected.
IMPORTANT : If incorrect sensing occurs due to sensor malfunction, etc., HELP32can be used to
prohibit plate ejection error sensing.
Timing If the variation in the amount of light received by the master ejection sensor during the making of 1 plate is less than a certain level (8 in the HELP5 display value), a plate ejection error is deemed to have occurred. HELP mode H-05 \ see p.244
2HELP mode H-05 value

63 Threshold value : Value without master + 8
Threshold value
00
Time Value without master : the photo receiving amount of the plate ejection sensor at the position where the first paper jam is detected after starting platemaking.
2. Rotation Control of the Roll-up Motor

If the roll-up motor is kept rotating when the master tip end is pulled to the ejection box in the plate detachment process, the drum is actuated by the master and the stop position slips. To prevent this, the roll-up motor is stopped when the master is detected by the master ejection sensor. (If the master is not detected by the master ejection sensor, the Roll-up motor is stopped by the timer.) 77
chap.2
Master Clump Opening / Closing Section
1. Description
The master clump on the drum unit is opened or closed by the two opening / closing levers' rotation operation. The opening / closing levers (one for the master attachment position, and the other for the master detachment position) are on the master clump opening / closing section on the main body rear side. The master clump is opened or closed during platemaking. Opening / closing operation is as follows:Master clump opening / closing lever (Plate attachment position) Master clump opening / closing section Master clump opening / closing lever (Plate detachment position)
Drum unit
23S0265
1) When platemaking starts, the drum unit rotates from the stop position to the opening / closing lever section (master detachment position) and it stops temporarily. (B mode)
2) Open the master clump to have the used master tip end gripped by the plate ejection unit.
3) Close the master clump, rotate the drum again and stop the drum at the next opening / closing lever section (master attachment position).
4) Open and close the master clump to have it grip the leading edge of the used master.
5) Rotate the drum, to wind the master onto it.
78
chap.2
2. Operation of Master Clump Open / Close Lever

(1) Structure
The following is the structure of the master clump opening / closing section viewed with the rear cover opened. The rotation stop position of the master clump opening / closing lever is determined by the clump motor and two cams. There are 3 rotation stop positions: A mode, B mode and C mode. Their functions are as follows:-
Master clump opening / closing lever
Master clump opening / closing lever Clump motor
Master clump B mode adjusting cam A / C mode adjusting cam B mode sensor A / C mode sensor
The drawing below is a section through the machine's interior, viewed from the control side.
Plate attachment position Plate detachment position
Master clump opening / closing section
Drum
2A mode
2B mode
2C mode
23S0266
79
chap.2
(2) Plate Attachment / Detachment Operation
80
chap.2
(3) Clump Opening / Closing Lever Position (A / B / C Mode)

Mode Photointerrupter stop position / state of sensor
A / C mode sensor (PS3)
Functions In the normal state or during printing, the master clump opening / closing lever turns out from the master clump opening / closing lever.
A m o d e
B mode sensor (PS4) Photointerrupting
Photopassing
B m o d e
B mode sensor (PS4) PhotointerruptinggPh oto-passing or Photopassing gPhotointerrupting
The master clump opening / closing lever pinch the master clump opening / closing arm.
Photo-interrupting
The master clump is open. This state occurs when the master is attached or detached.
C m o d e
B mode sensor (PS4) Photopassing
Photopassing
81
chap.2
(1) A / B / C Mode Sensor
Circuit
Clump motor (M3) Black Brown 2 1 Yellow Orange CN4-15 -16 Drive PCB unit CN1-1 -14 -32 5V Photo passing:0V Photointerrupting:5V 5V Photo passing:0V Photointerrupting:5V
A/C mode sensor(PS3) 1 2 3 Red Orange Blue CN10-3 -4 -5
5V
5V
B mode sensor(PS4) 1 2 3 Red Green Blue -9 -10 -11
5V
5V
Main PCB Unit
CN1-19
23S0329E
Operation / Sequence
The mode is detected under the following conditions 2A mode When the B mode sensor (PS4) is photointerrupted, the A / C mode sensor (PS3) detects the edge of photointerrupting f photopasing. *With the power ON, the A mode is determined when the B mode sensor is in the photointerrupting state and the A/C mode sensor is in the photopassing state. If not in the A mode with the power ON, the master clump opening / closing lever rotates to the B mode and stops. When the lever stops at the B mode, the drum rotates with the drum rotation switch and returns to the A mode at the stop position. 2B mode When the A/C mode sensor is photointerrupted, the B mode sensor detects the edge of photointerrupting / /photopassing or photopassing - photointerrupting. 2C mode When the B mode sensor is photopassing, the A/C mode sensor detects the edge of photointerrupting f photopassing. 82
chap.2
4. Returning Operation Flowchart When the Power Is Cut Off Accidentally

The machine returns to the initial state automatically when the power is turned off mistakenly during processing platemaking, plate-detaching and plate-attaching simultaneously or when the power returns after it is interrupted.
Power ON Power ON
Detachment/attachment process
Is the state the same as the previous state (before the power is turned OFF)?
"PLEASE WAIT" display
Process other than detachment/attachment
Attachment/detachment operation continues
"PLEASE WAIT" lights out
no "MASTER SET MISS" displayed? yes Open the document receiving tray
Remove the mis-set master
Close the document receiving tray
OK monitor lights out Initial desplay
Standby
83
chap.2
c Paper Feed Section
cPaper feed section

1. Description
Feeding of the paper is performed by the paper separator (employing the center separation method) and paper feed roller (there is no corner finger). Elevation of the feed tray is powered by the elevator motor. Paper fed by the paper separator and paper feed roller is fed further by the timing roller and guide roller to the point where its leading edge is sandwiched between the drum and the press roller. Then the pression of the timing roller and guide roller is released (by moving the guide roller upward several mm), so that the paper is fed through at a speed equal to the circumferential speed of the drum and press roller. The press roller sensor senses the paper feed condition; if a feed error occurs, the message PAPER LEFT JAM is displayed. For details, see 1.Paper Jam Detection Timing in chapter 2 (n Paper ejection section). \See page 109
Drum Press roller Elevator motor DP-23S LPU (Long Paper Unit) P roll sensor Guide roller
Paper feed roller
Paper separator
Paper
Timing roller
Supplemental paper tray
Feed tray
23S0274
84
chap.2
2. Operation
(1) Rotation of the Paper Feed Roller and Timing Roller
When the main motor turns, the paper feed cam rotates, causing the paper feed segment and timing segment to execute the reciprocating motion shown below, which turns the pinion gear.
Paper feed roller Paper feed segment
Paper feed roller
Timing roller
Pinion gear
Timing segment
23S0223
85
chap.2
(2) Paper Feed Roller Drive

The paper feed roller is driven by the main motor via the timing belt and the paper feed clutch. The rotational timing depends on the ON/OFF state of the paper feed clutch and is controlled by the program.
Timing roller Paper feed clutch Main motor
Paper feed roller
23S0279
86
chap.2
(3) Driving of the Timing Roller

Timing roller is actuated to rotate by the pinion gear and spring clutch. When the paper feed cam rotates, the reciprocating motion of the timing roller segment is transmitted to the pinion gear, and the spring clutch works to rotate the Timing roller in the direction of conveyance.
Paper feed cam
Pinion gear
Spring clutch Spring clutch
Paper feed segment
Timing roller
23S0275
87
chap.2
(4) Escape the Guide Roller DP-21S/L

After the Press roller is pressed to the drum, the printing paper is gripped firmly with the drum and Press roller, the Guide roller is released from the Timing roller. This is called "escaped". Escape timing is within a period when the printing paper is conveyed about 10 mm after it is gripped with the drum and Press roller.
IMPORTANT : When the timing is too late, the printing paper is gripped at two places too long. Thus
master elongation and slippage occur. On the contrary, when the timing is too early, the printing paper is not gripped at all, and it is not well settled. Thus creasing of paper and dispersion of the printing position occurs.
Escape lever Drum
about 10mm
Escape cam
Guide roller Press roller Timing roller

23S0286
Escape cam Press roller Guide roller Drum
Timing roller
about 10mm
Paper
23S0287
88
chap.2
(4) Escape the Guide Roller DP-23S

* DP-21S / 21L : Option
After the Press roller is pressed to the drum, the printing paper is gripped firmly with the drum and Press roller, the Guide roller is released from the Timing roller. This is called "escaped". Escape timing is within a period when the printing paper is conveyed about 10 mm after it is gripped with the drum and Press roller.
IMPORTANT : When the timing is too late, the printing paper is gripped at two places too long. Thus
master elongation and slippage occur. On the contrary, when the timing is too early, the printing paper is not gripped at all, and it is not well settled. Thus creasing of paper and dispersion of the printing position occurs.
Drum Escape motor Escape lever
Escape sensor
Escape cam
about 10mm Guide roller Timing roller
Sensor plate
Press roller
23S0289
Escape cam Press roller Guide roller Drum
Escape motor
Timing roller
about 10mm
Paper
23S0290
89
chap.2
(5) Paper Feed Length

The paper feed length is the length by which the paper feed roller feeds out the print paper. When the paper feed roller feeds out the print paper, the guide roller is pressed against the timing roller and does not rotate; as a result, the paper arches up between the paper separator and the timing roller, since the distance between these two items is only 80mm, while the length by which the paper is fed out from the paper feed roller is 95mm. This arching has the effect of correcting any skewing of the paper (as the leading edge is held firm between the guide and timing rollers). It also has the effect of lessening the load on the timing roller when it feeds the paper through, thus minimizing slippage. For feed amount, the leading edge of the paper is detected by the loop sensor and paper feed is controlled by program.
Guide roller
Paper feed roller
Paper
Paper feed cam
Cam follower Paper separator
Timing roller
Paper feed sensor
23S0260
IMPORTANT : If paper feed length is too large: the arching dimension will be too large, and if the paper is
of a very stiff type, it will buckle up between the paper feed roller and the paper feed inlet (upper), causing a PAPER JAM error ("PAPER LEFT JAM"). If paper feed length is too small: the arching dimension will be too small, so that arching will be unable to correct skewing of the paper, and skewing and wrinkling will be liable to occur. Furthermore, the slippage that occurs when the timing roller feeds the paper through will be very large, resulting in printing position errors.
90
chap.2
3. Functions of parts
(1) Printing Position Adjusting Mechanism
The printing position is adjusted by changing the timing of the paper toward the drum with the PRINTING POSITION ADJUSTMENT , key on the control panel. Description When the PRINTING POSITION ADJUSTMENT , key on the control panel is pressed, the link cam is driven by the motor. As the link cam moves, the cam follower position (bearing) from the paper feed cam changes. Accordingly drive timing for the timing roller can be changed. 2Press the key ; Cam follower moves in the direction of : e Drive timing of the timing roller becomes earlier. Paper timing becomes earlier, and the picture image moves backward. 2Press the key ; Cam follower moves in the direction of : b Drive timing of the timing roller becomes later. Paper timing becomes later, and the picture image moves forward.
Standard position sensor Printing position motor Paper feed cam
STD
makes cam followPressing er move in the e direction
Top and bottom limit sensor Link cam
makes cam followPressing er move in the b direction

Timing roller
Cam follower
23S0258
91
chap.2
Circuit
Printing position motor (M6) Black Brown 2 1 Orange Yellow CN4-1 -2 Drive PCB unit CN1-1 -14 -32 5V Photo passing:0V Photointerrupting:5V 5V Photo passing:0V Photointerrupting:5V
Top and bottom limit sensor(PS10) 1 2 3 Red Gray Blue CN10-26 -27 -28
5V
5V
Standard position sensor(PS11) 1 2 3 Red White Blue -29 -30 -31
5V
5V
Main PCB Unit

23S0330E
Operation Top and bottom limit of print position is detected by the top and bottom limit sensor and the standard position sensor. The center position is detected by the standard position sensor.
2 Standard sensor: photopassing, Limit sensor: photointerrupting

The printing position is between the standard position and bottom limit.
2 Standard position sensor: photopassing, Limit sensor: the edge of photointerrupting - photopassing
is detected The printing position is at the bottom limit.
2 Standard position sensor: photointerrupting, Limit sensor: photointerrupting

The printing position is between the standard position and the top limit.
2 Standard position sensor: photointerrupting, Limit sensor: the edge of photointerrupting - photopassing
is detected The printing position is at the top limit. Operation with the Power ON The printing position returns to the standard position by operating with the power ON, depending on the sensor state as follows. 2When positioned between the standard position and the bottom limit: Rotate the printing position motor normally (CW) to return the printing position to the standard.
2When positioned between the standard position

and the top limit: Rotate the printing position motor reversely (CCW) to return the printing position to the standard.
92
CN1-19
chap.2
(2) Signal Lever

Description The signal lever is positioned at the back of the Guide roller / Timing roller. Whether the paper is fed by the Timing roller is detected mechanically. Operation The pinch lever is attached to the other end of the shaft to which the signal lever is attached. As the signal lever is jumped by the paper, the pinch lever also jumps. Accordingly the Press roller is out of control and rises. The above operation keeps the drum from dirts as the Press roller is in contact with the drum when the paper is not fed. As the Press roller sensor detects rising of the Press roller, Whether the paper is fed from the paper feed section to the printing section normally is detected indirectly.
Pinch lever
A
Press lever
P roll sensor Signal lever

Press roller
Guide roller
Timing roller
Paper
23S0277
View from Signal lever
Drum
Pinch lever
Press roller
Guide roller P roll sensor Timing roller

23S0257
93
chap.2
(3) Feed Tray (Elevator) Upper Limit Sensor

Description The feed tray (elevator) upper limit sensor senses decrease of the paper pile, and the upper limit position of the feed tray. It does so by detecting the up/down motion of the paper feed shaft. Circuits
Feed tray (elevator) upper limit sensor 5V 1 2 3 Red Light green Blue CN2-22 -23 -24 0 5V Photopass : 0V Photointerrupting : 5V 5V
Main P C B U nit
23S0301E
Operation Sensing of feed tray upper limit 2When the feed tray rises, the paper in it presses the paper feed roller upward, making the paper feed shaft lever (photointerrupter) rotate upwards about its fulcrum, until it no longer obstructs the sensors light beam. Restoration of the sensors light beam signals that the paper tray has reached the upper limit, and triggers stopping of the feed trays rise. Sensing of paper decrease 2As printing progresses and the paper decreases, the paper feed roller gradually descends, until it obstructs the sensors light beam. When this happens, the feed tray is raised until the light beam is restored. If the light beam is not restored within about 30 seconds of the sending of the RAISE FEED TRAY command, error E002 (elevator lock) is displayed.
Paper feed shaft lever Paper feed roller Paper tray upper limit sensor Fulcrum Paper
23S0224
94
chap.2
(4) Feed Tray (Elevator) Lower Limit Switch

Description This is a micro switch (SM6) that senses the lower limit position of the feed tray.
Circuits
Feed tray (elevator) lower limit switch Lower limit (PUSH) : OPEN 5V Light blue Light blue CN2-20 -21 5V 0
Main P C B U nit
23S0302E
Operation When the feed tray rises, the bracket disengages from the switch and the switch closes. When the feed tray descends to its lower limit position, the bracket engages the switchs actuator, opening the switch. If the switch does not open within about 30 seconds of the sending of the LOWER FEED TRAY command, error E002 (elevator lock) is displayed. 2Lower limit position
Feed tray lower limit switch
Actuator
Bracket
23S0114
95
chap.2
(5) Paper Sensor

Description Senses presence/absence of paper in the feed tray. When the paper in the tray runs out, the message "SET PRINT PAPER" is displayed and printing stops. Circuits
Paper sensor Closed when paper present Open when paper absent 1 2 3 Red Purple Blue CN2-25 -26 -27 0 5V Photopass : 0V Photointerrupting : 5V
5V
5V
Main P C B U nit
23S0303E
Operation When there is no paper, the lever moves away and the sensor opens. When paper is placed inside, the lever presses the actuator and the sensor closes. When an absence of paper is detected, the message "SET PRINT PAPER" is displayed on the operation panel. 2When absence of paper is sensed, platemaking, printing and test printing are not possible. 2If the paper runs out during printing, "SET PRINT PAPER" is displayed on the operation panel, printing is stopped, and the feed tray descends to its lower limit position. 2If the paper runs out during platemaking, operation continues until the end of the platemaking process, then operation stops (without proceeding to the printing process), and the feed tray descends to its lower limit position.
When there is paper placed :
When there is no paper :
Photointerrupting
Photopassing
Actuator Paper sensor

23S0226
96
chap.2
v Drum Driving Section
vDrum Driving Section

1. Description
Drum home / jam detection position sensor
Drum gear
Master attachment / detachment position sensor
(P roll sensor)
Main motor
Encoder
Encoder sensor
23S0248
97
chap.2
(1) Home Position / Jam Detection Position Sensor
The home position / jam detection position sensor detects the drum home position and jam detection position. 2The drum home position is the position where the drum stops at the same time when a beep sounds after the jog switch (drum rotator switch) is kept pressing. 2The jam detection position is the timing to check paper jamming in the paper ejection section. 2Paper jamming in the paper ejection section is checked in the above timing with the jam sensor (photoreceiving) and P roll sensor. Circuit
Drum home position / jam detection position sensor (PS5) 1 2 3 Red Yellow Blue CN10-6 -7 -8 0 5V Photopass : 0V Photointerrupting : 5V 5V
5V
Main P C B U nit
23S0304E
Operation The home position / jam detection position sensor is positioned while the drum is rotating as follows:2The home position is detected with the edge of photointerrupting / photopassing. 2The jam detection position is detected with the edge of photopassing / photointerrupting.
Drum home/jam detection position edge
Drum home/jam detection position sensor
Jam detection position edge

23S0249
98
chap.2
(2) Master Attachment / Detachment Position Sensor

The master attachment / detachment position sensor detects the drum stop position when the plate is attached or detached. It also detects the speed reducing timing for stopping at the printing speed and for pressing the JOG switch (drum rotator switch) . Circuit
Master attachment / detachment position sensor (PS6) 1 2 3 Red Purple Blue CN10-12 -13 -14 0 5V Photopass : 0V Photointerrupting : 5V 5V
5V
Main P C B U nit
23S0305E
Operation The following is the state of the master attachment / detachment position sensor while the drum is rotating. 2The master detachment position is detected with the edge of photopassing f photointerrupting. 2The master attachment position is detected with the edge of photointerrupting f potopassing. 2The drum speed is reduced to the slow (before-stop) speed at the plate detachment position before the drum stops.
Master attachment position
Master detachment position
Master detachment position edge
Master attachment position edge Master attachment / detachment position sensor

23S0250
99
chap.2
(3) JOG Switch (Drum Rotator Switch)

Description The drum rotates as long as the JOG switch (drum rotator switch) is pressed (within one rotation) and stops at the stop position with a beep. Circuit
JOG switch (drum rotator switch) (SW3) 5V Purple Purple CN2-8 -9 5V 0
Main P C B U nit
23S0306E
Sequence of Operation 2When the JOG Switch (Drum Rotator Switch) Is Pressed Down In the normal state, the drum rotates (within one rotation) when the JOG switch (drum rotator switch) is kept pressed and the drum stops at the stop position, reducing the speed to the slow (before-stop) speed at the first plate detachment position. When the P roll sensor is in the photopassing state (P roll ON) at the first plate detachment position, the drum passes the stop position without reducing the speed.

23S0014
JOG switch (drum rotator switch) (SW3)
100
chap.2
(4) Control of the Main Motor

Circuit
Main m otor P C B U nit Brown Brown Blue Blue CN4-1 -2 -3 -4 5V Red Gray Blue CN1-1 -2 -3 0 5V Photopass : 0V Photointerrupting : 5V 5V
DC24V
Encoder sensor (PS7) 1 2 3
Main motor (M1)
Blue Red
CN5-1 CN3-1 -2 -3 -4 -5 -6 Main 2 -26 -7 Main 3 Light blue -27 -2 -8 -28 Main 4 Purple
Orange Encoder dividing White Inter lock monitor -23
Black
Main 1 -25
GND
5V
CN11-21
-22
Main P C B U nit
23S0307E
101
-24
Gray
Blue
Red
chap.2
1. Rotation Speed Control by Encoder Sensor The encoder sensor detects the main motor rotation. The main motor PCB Unit controls the number of main motor rotations with the encoder sensor signal. The encoder sensor signal is transmitted to the main PCB Unit as encoder dividing signal (8 dividings). The number of main motor rotations is checked with the HELP01. HELP mode H-01 \ see p.238
2. Selecting the Speed The speed is selected with the main 1 - 4 on the main PCB Unit. The following are the speed depending on the pin state.
1st SPEED L L H L 2nd SPEED H L H L 3rd SPEED L H H L
STOP CN 11-25 -26 -27 -28 Main 1 Main 2 Main 3 Main 4 H
SLOW 1 L L L L
SLOW 2 H L L L
JOG L H L L
IMPORTANT : Slow 2 is applied to accelerating only. it is not used to reduce the speed. All the speeds
including slow 1 are accelerating speeds. if the slow 1 is not operated, all the other speeds are not operated.
102
chap.2
b Press Section
bPress Section
1. Description
Drum gear
Press lever Press roller P roll sensor

23S0251
(1) Press Roller Timing & Printing Area

Description In this machine, the master is rolled up to the drum, ink is transferred to the drum and the printing paper is pressed to the drum by the press roller to print. Printing is performed on only the sections that meet the following requirements.
(mm)
1) The sections of the master on which holes are made by processing platemaking. (platemaking area) 2) The hole sections of the drum. 3) The section of the drum pressed with the press roller. (the area pressed ON) When the pressed-on position is 0 under the normally adjusted conditions, relations among 1), 2) and 3) are as follows*-
DP-23S
Press ON length Drum hole section length Printing area length
DP-21L
DP-21S 356 315.3 300
360 365.3 355
DP-21L/23S : 365.3mm DP21S : 315.3mm

Center of the master clump shaft
Bottom end of the hole section
103
DP-21L/23S : 250mm DP21S : 210mm
chap.2
b Press Section
The press roller is ON (the press roller is pressed to the drum) or OFF by operating the press lever up and down with the cam inside the drum gear. Press roller : OFF
Drum Drum gear Cam
Press roller : ON
Cam Drum gear Drum
Press roller Press lever

23S0252
Adjusting the printing area means that the cam curve goes up and down as shown in the figure. The timing of drum ON / OFF varies depending on the cam curve`s up and down. The ON position is before the drum hole section, so the printing area is not influenced. (Do not shorten the printing area length as it is influenced.) The OFF position is only changed and the printing area is adjusted.
IMPORTANT : Do not press off later than the hole
Press OFF position
Press ON position
Printing area
Printing area
section end position since ink seeps from the bottom end of the master.
Drum hole section end
Drum hole section start
104
chap.2
b Press Section
(1) Press Roller (P Roll) Sensor
The P roll sensor detects up and down of the press roller. The press roller only ascends when the paper is fed from the paper feed section by the pinch lever. The P roll sensor also is used to know whether the paper is fed. Circuit
Press roll limit sensor(PS8) 5V 1 2 3 Red Light blue Blue CN10-15 -16 -17 0 5V Photopassing : 0V Photointerrupting : 5V 5V
Main P C B U nit
23S0308E
Operation The P roll sensor position varies depending on the press roller position as follows: When the press roller is OFF (DOWN) : photointerrupting When the press roller is ON (UP) : photopassing
Press roller : OFF

Pinch lever Drum
Press roller : ON
Pinch lever Drum
P roll sensor :photointerru pting
P roll sensor :photopassing
23S0253
105
chap.2
n Paper Ejection Section
nPaper Ejection Section

1. Description
In the paper ejection section the printed paper is removed from the drum and is ejected to the print tray.
DP-23S
Drum
Paper stripper finger
Paper ejection belt
Paper ejection fun Paper ejection clutch
Main motor
DP-21S/L
Drum
Paper ejection belt
Paper ejection fun
Main motor
23S00288
106
chap.2
2. Functions of Parts
(1) Paper Stripper Finger
Mechanical Structure and Operation In addition to the paper stripper finger installed in the center, there are two sub paper remover fingers on both sides. There is an air diffuser on the tip of the finger. Compressed air transmitted from the air pump is blowed out of this hole to detach the tip end of the paper from the drum.
Air pump
Sub paper stripper finger
Sub paper Paper stripper finger stripper finger

23S0278
To remove the paper from the drum firmly, the gap between the tip of finger and the drum surface and between the tip of finger and the corner of the master clump are adjusted as follows:Drum surface Approx 0.5mm

23S0247
107
chap.2
(2) Jam Sensor

Description The jam sensor photo-receiving element is installed on the paper ejection fan unit and detects whether the paper is ejected normally. When it is detected that the paper is not ejected normally, "PAPER RIGHT JAM" (ejection side) is displayed on the error display panel on the control panel. Circuit
Master ejection sensor photo-emitting PCB Blue 1 Gray Jam sensor photo-emitting PCB Blue 1 Pink Jam sensor photo-recieving PCB Pink Blue 2 4 -25 3 -24 2 6 -23 5 CN10-22
5V
2 1
5V CN10-18 -19 5V
Main PCB Unit
23S0309E
Operation The Jam photo-emitting PCB is installed in the master ejection box, and the photo-receiving PCB in the paper ejection fan unit. HIGH with the optical path interrupted. LOW with the optical path passing. There are two cases of interruption; interrupted by the paper and the master ejection box is open.
Master ejection box
Jam sensor(Photo-emitting)
Jam sensor(Photo-receiving)
Paper ejection fun unit
23S0255
108
chap.2
1. Paper Jam Detection Timing Description Paper jamming is divided into two types: "PAPER RIGHT JAM" (ejection side) and "PAPER LEFT JAM"(feeder side). Paper jamming is detected under the following conditions. When paper jamming is detected, "PAPER JAM" is displayed on the error display panel on the control panel, and the machine stops printing operation. The display is cleared by removing the cause of paper jam and pressing the STOP key or by restarting printing.
2Paper jamming on the ejection side
JAM1: The bottom end of the paper is not ejected. When the jam sensor (light-emitting and light-receiving) is interrupted at the timing of jam detection position edge (photopassing \ photointerrupting) of the drum home / jam detection position sensor PS5. JAM2: The tip end of the paper is not ejected. When the JAM sensor is not interrupted at all while the P roll sensor is in the state of photopassing (pressed ON). JAM (stop): When the JAM sensor is interrupted as the master ejection box is open when the machine stops. The display is cleared when the sensor is in the state of photopassing.
2Paper jamming on the feeder side
JAM3: The paper does not pass the signal lever though the paper is fed. The P roll sensor is not in the state of photopassing when the drum rotates twice after the paper feed solenoid is ordered ON. Sequence of Operation
A4 LG B4
A4 LG B4
A4 LG B4
Drum home/jam detection position sensor Master attachment/detachment position sensor Signal lever
Jam sensor(Photo-emitting)
Jam sensor(Photo-receiving)
P roll sensor
DP-23S
23S0256
109
chap.2
(3) Paper aligning mechanism

Description Paper can be aligned neatly by considering the ejection angle. Adjustments should be made in accordance with paper thickness. For thinner paper: Set the lever in the upper position. For thicker paper: Set the lever in the lower position. * Although the lever is usually set at the intermediate position for paper of normal thickness (65g/m2), the lever position should be adjusted depending on the condition of the paper.
Lever Thinner paper Normal(65g/ ) Ticker paper
23S0285
110
chap.2
m Drum Section
mDrum Section
1. Description
The ink control section is in the drum unit. The ink control section is supplied with ink in the ink pack attached to the drum unit by the motor. The ink control section has an ink detection function, and is always supplied with a fixed amount of ink. Printing darkness is adjusted by changing the gap between the squeegee roller and the ink roller. Five color inks are available: black, red, blue, green and brown. Perform color printing to replace the drum unit for each color. (Press the drum rotation switch to the drum home position to replace the drum unit.) In this machine, whether there is a drum or not is detected. If the drum is not attached properly, it is taken as "DRUM NOT SET", and "DRUM NOT SET" is displayed on the control panel.
Ink detection PCB unit
Ink motor
Squeegee roller
Ink roller
Ink pack
111
chap.2
m Drum Section
2. Circuit
Drive PCB Unit 23V CN2-1 -2 Orange Pink 2 8 Orange Pink 1 Brown 2 Black Ink motor (M7)
Ink detection PCB Unit 23V -3 -4 -5 Blue Brown Black 3 9 4 Blue Brown Black 3 Blue 1 Brown 2 Black CN1-3 -1 -2
23S0310E
112
chap.2
m Drum Section
(1) Ink Detection
Description The ink amount variation in the ink control section is read by the electric capacity variation between the detection needles on the ink detection PCB Unit and the GND and the ink signal is output to the main PCB Unit. The main PCB Unit controls the motor ON and OFF by this signal. When NO INK continues while the drum rotates 20 times (the number of drum unit rotations; it varies depending on the printing speed.*) during printing, it is determined that the ink pack is empty, "CHANGE INK" is displayed and the machine stops printing. \See page 115
113
chap.2
m Drum Section
1. LED Display and Output Signal on the Ink Detection PCB Unit 2When the electric capacity variation between the detection needles on the ink detection PCB Unit and GND is over the threshold value, the LED on the ink detection PCB Unit lights up and the ink signal (0V) is output.
Ink detection PCB unit LED No ink Ink Light out Light up CN1-2 +5V 0V
2Timing of the LED and the ink motor operation is as follows. The ink motor works during printing (driving output signal). 2Ink detection PCB unit
114
chap.2
m Drum Section
2. "CHANGE INK" Display Timing When HIGH (5V) is output by detecting ink while the drum continues to rotate 20 times (the number of rotations varies depending on the printing speed.*) during printing, it is detected that the ink pack is empty, "CHANGE INK" is displayed on the error display, and printing stops. At the same time the power for the ink motor is turned off.
*The drum rotates until "CHANGE INK" is displayed after HIGH is output from the ink detection PCB unit during printing. The number of drum rotations varies depending on the printing speed as follows:1 17 2 20 3 24
Printing speed
Number of rotations
115
chap.2
m Drum Section
(2) Ink Pump

Description The ink control section in the drum is supplied with ink in the ink pack by driving the ink motor. Mechanical Structure
Operation The piston performs suction and release operation by moving up and down.
When the piston moves up, it draws ink from the ink pack into the pump.
When the piston moves down, the pump releases ink.
116
chap.2
m Drum Section
(3)Drum Switch
Description The drum switch detects whether the drum is installed to the machine. When it is detected that there is no drum installed, "DRUM NOT SET" is displayed on the error display panel on the control panel the machine stops operation. When no drum is detected during operation, all the operations stops emergently. Circuit
Drum switch (MS4) 5V White White CN2-10 -11 5V 0
Main P C B U nit
23S0331E
Operation When the drum is attached to the main body, the cam unit covers the pin and is locked firmly. The difference of the cam unit prevents the cam unit from being loosened due to the machine vibration. When the pin is at the bottom of the cam unit difference, the drum SW is open as shown in the figure. When the pin is over the cam unit difference, the drum SW is closed. 2Drum installed
Lever
2No drum
Lever
Pin Switch Cam unit

23S0280
117
chap.2
m Drum Section
(4) Front Cover Open / Close Detection Switch

Description The front cover switch detects opening and closing of the front cover. "FRONT COVER OPEN" is displayed on the error display panel on the control panel, when it is detected that the front cover is open. When the front cover is open, platemaking and printing is not performed. When the front cover open is detected during printing, the machine stops immediately. (When the front cover open is detected during platemaking, the machine stops before processing printing.) Circuit
Front cover switch (MS5) 5V Light blue Light blue CN2-12 -13 5V 0
Main P C B U nit
23S0332E
Operation When the front cover is closed, the lever presses the switch and is closed. When the front cover is open, the lever is apart from the switch and is open.
Switch
Front cover
2When the front cover is closed :

Lever
2When the front cover is open :

Lever
Switch
Switch
23S0272
118
chap.2
, Option
,Option
(1) TAPE CLUSTER
Description A certain length of tape is fed and cut from the TAPE CLUSTER to finish printing the number of sets in the cluster printing operation. The operation is continued to process the number of sets.
Cluster tape
TAPE CLUSTER
23S0028
*Printing does not stop when the tape runs out during printing. The number of sheets for 1 set to be processed is 1 - 9999 sheets. The number of sets for 1 classification to be processed is 1 - 99 sets. 2When the number of sets is input without a TAPE CLUSTER (optional), the following is operated. Printing stops at the timing of feeding tape, Press the PRINT key again to start printing. (Manual clustering)
IMPORTANT :
When attaching the TAPE CLUSTER, set the mode to the HELP mode 28 with TAPE CLUSTER. (For further details, refer to the list of the HELP modes. If it is not set, the TAPE CLUSTER does not work.) HELP mode H-28 \ see p.267
Operation 1) The TAPE CLUSTER starts to feed the tape from the last 10 sheets for the set. A fixed length of the tape is fed and is cut after completing printing the set amount. This operation is repeated until the last set is processed. The fed amount of tape is different between the large and small classifications. When all the sets for 1 classification are processed, the fed amount of tape is longer (large classification). When all the sheets for 1 set are processed, the fed amount of tape is shorter (small classification). Fed amount of tape for small classification: about 250mm (15%) Fed amount of tape for large classification: about 370mm (15%) 2) When the number of sheets for the set is less then 10 sheets, the tape is fed at the same time when printing starts. When the number of sheets is printed before a fixed amount of tape is fed, printing for the next set is discontinued until the tape is fed. (Paper feeding stops. The drum rotates at a low speed.) 119
Chapter 3
z Exterior.......................................................................122 (1) Removal of the Document Tray...........................122 (2) Removal of the ADF Front / Rear Cover.............122 (3) Removal of the Document Cover.........................122 (4) Removal of Main PCB Cover...............................123 (5) Removal of Battery PCB Unit and Main PCB Unit.....................................123 (6) Removal of Front Cover.......................................124 (7) Removal of Control Panel ....................................124 (8)Removal of Control Panel PCB ............................124 (9) Removal of LCD Panel........................................125 (10) Removal of Drive PCB Unit and DC Regulated Power Supply ......................125 (11) Removal of Rear Cover ......................................126 (12) Removal of the Document Receiving Tray (Top Cover)..........................................................126 x Scanner Section ........................................................127 (1) Removal of ADF Cover ........................................127 (2) Removal of Document Sensor..............................127 (3) Removal of ADF Feed Roller ...............................128 (4) Removal of ADF Paper Separator Unit ..............128 (5) Removal of Scanner JAM Sensor (Photo-receiving) .................................................129 (6) Removal of Timing Belt .......................................129 (7) Removal of Scanner Clutch .................................130 (8) Removal of ADF Cover Opening / Closing Switch ......................................................130 (9) Removal of Scanner Stepping Motor ..................131 (10) Removal of Scanner Unit ..................................132 (11) Removal of Document Position Sensor.............132 (12) Removal of Inverter PCB Unit .........................133 (13) Removal of Lamp Unit ......................................134
Mechanism
c Platemaking / Master Feed and Ejection Section...135 Master Feed Section ...........................................135 (1) Removal of Cutter Unit .......................................135 (2) Removal of End Mark Sensor PCB Unit ............136 (3) Removal of Thermal Head...................................137 (4) Removal of Master Feed Unit .............................138 (5)Removal of Master Feed Stepping Motor ............139 Master Ejection Section ......................................140 (1) Removal of Master Ejection Box .........................140 (2) Removal of Jam / Master Ejection Sensor (Photo-emitting PCB Unit)..................................141 (3) Removal of Rollup Motor .....................................141 Master Clump opening/Closing Section ...........142 (1) Removal of Master Clump Opening / Closing Unit .........................................................142 (2) Removal of Clump Motor.....................................142 (3) Removal of Timing Belt .......................................143
120
v Paper Feed Section....................................................144 (1) Removal of Paper Sensor......................................144 (2) Removal of Elevator Lower Limit Switch ...........144 (3) Removal of Paper Feed Roller ..............................145 (4) Removal of Paper Separator Unit........................145 (5) Removal of Paper Feed Clutch Unit ....................146 (6) Removal of Paper Feed Sensor.............................147 b Drum Driving Section ................................................148 (1) Removal of Sub-Frame .........................................148 (2) Removal of Drum Gear.........................................149 n Paper Ejection Section ..............................................150 (1) Removal of Paper Stripper Finger / Sub Paper Stripper Finger...................................150 (2) Removal of Paper Ejection Fan Unit ...................151 (3) Removal of Paper Ejection Belt ...........................152 (4) Removal of Jam Sensor (Photo-receiving PCB Unit)..................................152 m Drum Section .............................................................153 (1) Removal of Screen ...............................................153 (2) Removal of Master Clump....................................154 (3) Removal of Base Unit...........................................154 (4) Removal of Outer Frame (Right) Unit.................155 (5) Removal of Outer Frame (Left) Assy...................156 (6) Removal of Inner Frame ......................................157 (7) Removal of Ink Pump ...........................................158 (8) Removal of Ink Motor...........................................158 (9) Removal of Ink Detection PCB Unit....................159
WARNING
Always remove the power cord plug from the outlet before starting work.
121
chap.3
z Exterior
z Exterior
(1) Removal of Document Tray
1) Lift the document tray directly upward, and remove the document tray by pulling it off the pins of the scanner unit.
Document tray Pins
23S0032
(2) Removal of ADF Front / Rear Cover

1) Remove the document tray. 2) Open the ADF cover. 3) Remove the 2 screws indicated, then remove the front cover. 4) Remove the 2 screws indicated, then remove the rear cover.
ADF cover Rear cover Front cover Screws
Screws
23S0033
(3) Removal of Document Cover

1) Carry out (1) and (2) above. 2) Remove the 2 screws indicated, then remove the document cover.
Document cover Screw
Screw
23S0034
122
chap.3
z Exterior
(4) Removal of Main PCB Cover

1) Carry out (1) through (3) above. \See page 122
Main PCB cover Screws
2) Remove the 4 screws indicated, then remove the main PCB cover.
Screws
23S0035
(5) Removal of Battery PCB Unit and Main PCB Unit WARNING
Always remove the power cord plug from the outlet before replacing a PCB Unit. 1) Carry out (1) through (3) above. \See page 122
Screw Battery PCB unit
Screw
2) Remove the connectors: Battery PCB Unit: 1 connector Main PCB Unit: 11 connectors 3) Remove the mounting screws, and replace the PCB units. Battery PCB Unit: 2 spacers Main PCB Unit: 4 screws
Screws
Screw
Screw
Main PCB unit

23S0062
123
chap.3
z Exterior
(6) Removal of Front Cover

Screw
1) Open the front cover, and take out the drum unit. 2) Open the document receiving tray and the master ejection box. 3) Remove the 7 screws indicated, then remove the front cover.
Screw
Screw Screws Screw Front cover

23S0056
(7) Removal of Control Panel

1) Remove the previously mentioned (3), (4), (6), and (2) ADF cover (R). \See page 122 2) Disconnect the connector. 3) Open the top cover. 4) Remove the two screws and carefully pull the panel out, being careful to not damage the panel.
Screw Control panel
Connector Screw
23S0057
(8) Removal of Control Panel PCB

1) Remove the preciously mentioned (6) and (7). 2) Pull out the stoppers on each side of the connetor and detach the LCD code. 3) Remove the one screw and remove the bracket. 4) Remove the 11 screws and remove the control panel PCB.
Stopper Control panel PCB unit
LCD cord
Connector
Brack-
Screws
Screws
23S0058
124
chap.3
z Exterior
(9) Removal of LCD Panel

1) Remove the previously mentioned (6) and (7). 2) Pull out the stoppers on each side of the connetor and detach the LCD code. 3) Remove the two screws and remove the LCD panel.
Stopper Bracket Screw
LCD cord
Connector
Screw
LCD panel
23S0059
(10) Removal of Drive PCB Unit and DC Regulated Power Supply WARNING
Always remove the power cord plug from the outlet before replacing a PCB Unit. \See page 124
Drive PCB unit
1) Remove the front cover.
Screws
2) Remove the connectors of. Drive PCB Unit (8 connectors) DC regulated power supply (3 connectors) Mini Drive PCB Unit (connector) DP-23S 3) Remove the mounting screws, and replace the PCB units. Drive PCB Unit: 4 screws
DP-23S Screws Regulated power supply Mini Drive PCB unit

23S0063
Screws Screws
125
chap.3
z Exterior
(11) Removal of Rear Cover

1) Remove the 2 screws indicated, then remove the rear cover.
Rear cover
Screws
Screws
23S0060
(12) Removal of Document Receiving Tray(Top cover)

1) Open the document receiving tray. 2) Remove the 2 screws indicated, then remove the hinge. 3) Remove the rear cover. 4) Remove the screw indicated, then remove the brackets. 5) Remove the document receiving tray.
Document receiving tray(Top cover) Screws
Hinge Bracket
Screw
23S0061
126
chap.3
x Scanner Section
x Scanner Section
(1) Removal of ADF Cover
1) Remove the ADF front / rear covers. \See page 122 2) Remove the 2 screws. 3) Remove the screws on either side of the scanner unit, and remove the hinges. 4) Remove the ADF cover.
Scanner unit Screw
ADF cover
Screw Hinge Screw

23S0041
(2) Removal of Document Sensor

1) Remove the ADF cover. 2) Remove the screw, and slide the bracket in the direction of an arrow to remove. 3) Remove the screw, and remove the sensor bracet. 4) Disconnect the connector, and remove the document sensor.
Bracket
Document sensor Screw Connector
Screw
23S0044
127
chap.3
x Scanner Section
(3) Removal of ADF Feed Roller

\See page 127 1) Remove the ADF cover. 2) Remove the screw indicated, and slide the ADF feed shaft in the direction of the arrow.
ADF feed shaft Screw
23S0045
3) Remove the E-rings, and remove the ADF feed roller.

E-ring Bush E-rings E-rings
Roller Roller ADF feed roller

23S0047
(4) Removal of ADF Paper Separator Unit

1) Carry out (1) and (2) above. \See page 127 2) Remove the ADF paper separator unit.
ADF paper separator unit
23S0046
128
chap.3
x Scanner Section
(5) Removal of Scanner JAM sensor (Photo-receiving)

Screw Screw
1) Remove the 2 screws indicated, and remove the ADF cover. \See page 128 2) Remove the ADF feed shaft. 3) Remove the 2 screws indicated, and remove the ADF feed inlet.
ADF feed inlet Screw
ADF cover
Screw
23S0042
4) Remove the screw, together with the bracket. 5) Disconnect the connector. 6) Remove the scanner JAM sensor.
Screw Sensor Bracket Connector
Scanner JAM sensor
23S0043
(6) Removal of Timing Belt

1) Remove the ADF front cover. \See page 122 2) Loosen the tension's fixing screw. 3) Pull the timing belt off the pulley, and remove the timing belt.
Tension Screw
E-ring
Pulley Timing belt

23S0048
129
chap.3
x Scanner Section
(7) Removal of Scanner Clutch

1) Remove the ADF rear cover. \See page 122 2) Remove the document cover. \See page 122 3) Disconnect the 2 connectors. 4) Remove the screw indicated, and remove the angle. 5) Remove the scanner clutch.
Screw Scanner clutch Screw
Connectors
23S0036
(8) Removal of ADF Cover Opening / Closing Switch

1) Remove the ADF rear cover. \See page 122
ADF cover opening / closing switch
2) Remove the 2 terminals. 3) Remove the 2 screws indicated, and remove the ADF cover opening / closing switch.
Screws
Terminals
23S0039
130
chap.3
x Scanner Section
(9) Removal of Scanner Stepping Motor

1) Remove the ADF rear cover. \See page 122 2) Remove the document cover. \See page 122 3) Remove the 4 screws indicted, and remove the motor cover.
Screws
Screws Motor cover

23S0037
4) Disconnect the connector. 5) Remove the 2 screws indicated, and remove the scanner stepping motor.
Screw Scanner stepping motor Connector
Screw Gear
23S0040
131
chap.3
x Scanner Section
(10) Removal of Scanner Unit

1) Remove the document tray. \See page 122
Scanner unit Screws
2) Remove the ADF front / rear covers. \See page 122 3) Remove the document cover. \See page 122
4) Disconnect the 4 connectors. 5) Remove the 4 screws indicated, and remove the scanner unit.
Screws 4 connectors
23S0038
(11) Removal of Document Position Sensor

1) Remove the scanner unit. 2) Remove the 4 screws indicated, and remove the guide plate.
Screws
Guide plate
Screws
23S0050
3) Disconnect the connector. 4) Remove the screw indicated, and remove the document position sensor.
Screw Document position sensor Connector
23S0052
132
chap.3
x Scanner Section
(12) Removal of Inverter PCB Unit WARNING

Always remove the power cord plug from the outlet before replacing the Inverter PCB Unit. 1) Remove the scanner unit. \See page 132
Screw
Guide plate unit
Screw
2) Remove the 2 screws indicated, and remove the guide plate unit.
23S0051
3) Disconnect the 2 connectors indicated, and remove the inverter PCB unit.
Connectors
Inverter PCB unit
23S0053
133
chap.3
x Scanner Section
(13) Removal of Lamp Unit

1) Remove the scanner unit. \See page 132
Bracket Screw Cord clamp Connector
2) Remove the 2 screws indicated, and remove the guide plate unit. \See page 133(12) w 3) Remove the cord clamp. 4) Disconnect the connector.
Lamp unit
23S0054
5) Remove the screw indicated, and slide the bracet in the direction of an arrow to remove. 6) Remove the lamp unit.
Bracket
Screw Lamp unit
23S0281
Reinstallation
Insert the lamp unit's grooves into the slots in the brackets.
Lamp unit IMPORTANT : Be careful not to break the lamp.
Groove
Groove
23S0282
134
chap.3
c Platemaking/Master Feed and Ejection Section
c Platemaking / Master Feed and Ejection Section

Master Feed Section
(1) Removal of Cutter Unit
1) Open the document receiving tray, and take out the master roll. 2) Remove the 4 screws indicated, and remove the cover F and R. 3) Disconnect the 1 connectors indicated. 4) Remove the screw indicated, and remove the stopper.
Screws Stopper Cover F Screw
Connector
Screws
Cover R
23S0065
5) Open the master cover. 6) Remove the 2 screws indicated, and remove the cutter unit.
Master cover Cutter unit
Screw
Screw
WARNING
Keep hands and fingers away from the cutter unit's blades. Do NOT touch the blades.
23S0066
135
chap.3
(2) Removal of End Mark Sensor PCB Unit.

1) Open the document receiving tray, and take out the master roll. 2) Open the master cover. 3) Remove the 2 nuts with a spanner, and remove the cover.
Cover Nut Nut
23S0070
4) Remove the 2 screws. 5) Disconnect the connector indicated, and the end mark sensor PCB unit.
Connector
Screws
Cover
End mark sensor PCB unit
23S0071
136
chap.3
(3) Removal of Thermal Head

1) Open the document receiving tray, and take out the master roll. 2) Open the master cover. 3) Remove the 2 screws indicated, and remove the guide plate.
Guide plate Screw Screw
23S0067
4) Remove the screw indicated, together with the collar. 5) Disconnect the thermal head's 2 connectors, and remove them together with the bracket.
Screw,collar
Connectors
23S0068
6) Remove the 2 screws together with the collars, and remove the thermal head.
IMPORTANT : Do not touch the heat emission par ts of the thermal head. The thermal head is also liable to corrode. To avoid corrosion, keep the head free of moisture and salinity, and do not touch its heat emission parts. Touching these parts could scratch them. Reinstallation IMPORTANT : When the thermal head is replaced, Collar Screw Collar Screw
Do not touch the heat emission parts
Thermal head
23S0069
set the HELP 44 DIP switch. HELP mode H-44 \ see p.280
137
chap.3
(4) Removal of Master Feed Unit

1) Open the document receiving tray, and take out the master roll. 2) Take out the drum unit. 3) Remove the front cover. \See page 124 4) Remove the under cover's 4 screws, and remove the under cover.
Under cover
Screws Screws
23S0072
5) Remove the 2 covers shown in the figure. 6) Disconnect the 2 connectors indicated. 7) Open the master cover. 8) Remove the guide plate. \See page 137
Connectors
Cover R Screws
23S0073
9) Remove the bundle wire from the 2 connectors of the thermal head PCB and the clamp. \See page 137 10) Close the master cover. 11) Disconnect the 4 connectors. 12) Remove the 6 screws indicated, and remove the master feed unit.
Master feed unit
Connectors Screw
Screws
Screws
23S0074
138
chap.3
(5) Removal of Master Feed Stepping Motor

1) Remove the master feed unit. \See page 138
Master feed stepping motor
2) Remove the 4 screws. 3) Remove the bush indicated, and remove the mater feed stepping motor.
Screw
Bush
Screws
23S0075
139
chap.3

(1) Removal of Master Ejection Box
1) Remove the rear cover. 2) Disconnect the 3 connectors. 3) Remove the cord band. \See page 126
Connector
Connector
Cord band
Connector
4) Remove the screw.

Screw
5) Remove the 4 screws indicated, and remove the master ejection box.
Master ejection box
Screws
140
chap.3
(2) Removal of Jam / Master Ejection Sensor (Photo-emitting PCB Unit)

1 ) Remove the master ejection box. \See page 140 2) Remove the respective photo-emitting PCB units by removing the 2 screws.
Master ejection sensor photoemitting PCB unit Screw
Jam sensor photo-emitting PCB unit
(3) Removal of Roll - up Motor

1) Remove the master ejection box. \See page 140 2) Remove the 1 screw indicated, and remove the cover.
Cover Screw
3) Remove the timing belt from the pulley at the part shown by the arrow. 4) Remove the 3 motor mounting screws indicated, and remove the roll - up motor.
Timing belt
Reinstallation IMPORTANT : Do not forget to adjust the tension
after the motor is attached. \See page 165

Screws Motor Pulley
141
chap.3
Master Clump opening/Closing Section

(1) Removal of Master Clump Opening / Closing Unit
1) Remove the rear cover. \See page 126 2) Remove the drum. 3) Move the position of the master clump opening / closing lever to the mode other than A mode. (Use the HELP 20) HELP mode H-20 \ see p.260 4) Turn the power off and turn it on again. The opening / closing lever moves to the B mode and stops.
5) Pull out 3 connectors. 6) Remove 3 screws to take out the opening / closing unit.
Screws Connector
Screws Master clump opening / closing unit Connectors

23S0077
(2) Removal of Clump Motor

1) Remove the master clump opening / closing unit. 2) Loosen the set screw to remove the gear. 3) Remove 3 screws to take out the motor.
Clump motor Screws Set screw
Screw
23S0078
142
chap.3
(3) Removal of Timing Belt

1) Remove the master clump opening / closing unit. \See page 142 2) Loosen 2 screws to loosen the tension as shown in the figure.
Tension Screws
23S0079
3) Remove the screw to remove the angle. 4) Remove the timing belt.
Screw
Screw
Timing belt
23S0080
Reinstallation
Adjust tension by adjusting the master feed master clump opening/closing lever and master ejection master clump opening/closing lever. Then fit the timing belt on. \See page 166
Position hole
Master ejection master clump opening/closing lever
IMPORTANT : Adjust the A, B and C modes after
the master clump opening / closing unit is attached to the printer main \See page 167 body.
Master feed master clump opening/closing lever Main frame R Position hole
Master clump opening/closing unit

23S0082
143
chap.3
v Paper Feed Section

(1) Removal of Paper Sensor
1) Access HELP mode H-02, and use it to raise the elevator to its uppermost position. HELP mode H-02 \ see p.241
Feed tray
23S0083
2) Disconnect the connector, and remove the paper sensor.
Paper sensor
Connector
23S0084
(2) Removal of Elevator Lower Limit Switch

1) Remove the front cover. \See page 124 2) Remove the 2 screws indicated, then remove the bracket. 3) Disconnect the connector, and remove the elevator lower limit switch.
Screws Reinstallation IMPORTANT : After reinstalling the elevator lower Elevator lower limit switch
23S0085
Connector
limit switch, carry out adjustment of its clearance. \For adjustment method see page 173
144
chap.3
(3) Removal of Paper Feed Roller

1) Remove the screw indicated, and slide the paper feed shaft in the direction of the arrow.
Screw
Paper feed shaft
23S0086
2) Loosen the set screw indicated, and remove the paper feed roller.
Reinstallation
Paper feed roller
Paper feed rollers
Reinstall the paper feed roller so that the set screw is positioned at the paper feed roller shaft's counter bore.
IMPORTANT : Do not use an old paper feed roller Set screw Set screws
23S0087
together with a new one.
(4) Removal of Paper Separator Unit

1) Loosen the set screws indicated, and move the 2 paper feed rollers clear of the paper separator unit. 2) Remove the paper separator unit.
Reinstallation IMPORTANT : After reinstalling the paper separaSet screws
tor unit, carry out adjustment of its clearance. \See page 171
Paper separator unit Paper feed rollers

23S0088
145
chap.3
(5) Removal of Paper Feed Clutch Unit

\See page 126 1) Remove the rear cover. 2) Disconnect the connector. 3) Remove the screw indicated, and disconnect the paper feed shaft from the coupling.
Connector Screw Paper feed shaft
23S0089
4) Remove the 3 screws indicated, and remove the bracket. 5) Remove the 2 screws indicated, and remove the bush.
Screws
Bush
Screw
Bracket Screws
23S0090
6) Remove the E-ring. 7) Remove the adjustment washers.
E-ring
Adjust washers
23S0091
8) Remove the clutch unit coil, loosen the 2 adjust bolts, and remove the clutch body.
Adjust washers E-ring
Clutch body Clutch unit coil

23S0092
146
chap.3
(6) Removal of Paper Feed Sensor

1) Remove the paper feed shaft. \See page 145 (3) q 2) Remove the paper separator unit. \See page 145 3) Remove the 4 screws indicated, and remove the bracket.
Screws Screws Bracket Paper feed shaft
23S0093
4) Disconnect the connector. 5) Remove the screw indicated, and remove the paper feed sensor.
Paper feed sensor Screw
Connector
23S0094
147
chap.3
b Drum Driving Section

(1) Removal of Sub-Frame
1) Remove the rear cover. \See page 126 2) Remove the 7 screws indicated, and remove the pump unit.
Screws Pump unit Screw Screw
Screws
23S0095
3) Disconnect the 6 connectors. 4) Remove the 11 screws indicated, and remove the sub-frame.
Screw Sub-frame
Screw
Screws Screw
Screw
Screws
23S0096
148
chap.3
(2) Removal of Drum Gear

1) Remove the rear cover. \See page 126 2) Remove the Sub-frame. \See page 148 3) Remove the 2 E-rings, and remove the links.
Links E-ring
E-ring
23S0097
4) Remove the 2 screws indicated, and remove the drum gear.

Screws
Drum gear
23S0098
149
chap.3

(1) Removal of Paper Stripper Finger / Sub Paper Stripper Finger
1) Open the master ejection box. 2) Remove the set screws. 3) Remove the paper stripper finger and sub paper stripper fingers from the shaft.
Sub paper stripper fingers
4) Take out the paper stripper finger and sub paper stripper fingers from the pipe.
Pipe Pipe
Reinstallation IMPORTANT : Adjust the paper stripper finger
after it is installed. \See page 180

Paper stripper finger Sub paper stripper finger
150
chap.3
(2) Removal of Paper Ejection Fan Unit

1) Remove the rear cover. \See page 126 2) Disconnect the connector. 3) Open the front cover, and remove the drum. \See page 124 4) Remove the front cover. 5) Disconnect the connector. 6) Open the master ejection box. 7) Remove the 2 screws from the cover, and remove the cover.
Cover Screws
23S0099
Connector
Connector
8) Remove the 6 screws indicated, and remove the jump plate F/R units.
Jump plate F unit
Jump plate R unit
Screws
Screws
23S0100
9) Remove the 4 screws, and pull out the paper ejection fan unit sliding in the direction of an arrow.
Paper ejection fan unit
Screws
Screws
23S0101
Reinstallation
Insert the driving shaft coupler to install the paper ejection fan unit.
Drive shaft coupler (Paper ejection fan unit)
23S0105
151
chap.3
(3) Removal of Paper Ejection Belt

1) Remove the paper ejection fan unit. \See page 151
Static removal brush
2) Remove the 2 screws from the static removal brush, and remove the static removal brush.
Screws
23S0102
3) Remove the 2 screws from the ends of the shaft, and remove the shaft. 4) Stretch the belts and install them oriented as shown in the figure.
Paper ejection belts
Screw Shaft
Screw
23S0103
(4) Removal of Jam Sensor (Photo-receiving PCB UNIT)

1) Remove the paper ejection fan unit. \See page 151 2) Pull the paper ejection belts wider apart to expose the screws, and secure the belts in that position. 3) Remove the 2 screws securing the sensor mounting angle, and remove the angle.
Remove the 2 screws with a driver
Paper ejection belts
23S0104
4) Remove the 2 screws from the sensor PCB, and remove the PCB.
IMPORTANT : Do not lose the 2 spacers.
Jam sensor
Screws
Spacers
152
chap.3
m Drum Section
m Drum Section
(1) Removal of Screen
Screw Screen
1) Remove the drum. 2) Remove the clamp on the bottom end screen bar to pull out the screen bar. 3) Remove 2 set screws on the top screen bar to pull out the screen bar. 4) Remove the screen from the drum.
IMPORTANT : Do not rotate the drum reversely.
Bottom end screen bar Clamp
Top end screen bar Screw
Screw
Reinstallation
1) Pass the top end screen bar through the screen (top end side). 2) Attach the top end screen bar to the drum.
IMPORTANT : Do not mistake the bottom end of
Top end screen bar Screw
Screen
Screw
the screen for the top end.
20mm (bottom end side)
58mm (top end side)
3) Pass the bottom end screen bar through the screen (bottom end side). 4) Hold the bottom end screen bar in parallel with the drum and roll it up to the drum rotating the drum normally.
Bottom end screen bar
5) Tighten the screen bar with the clamp.

IMPORTANT : The stainless screen does not return
Bottom end screen bar
to the original state once it is folded. Be careful to handle the screen.
Clamp
153
chap.3
m Drum Section
(2) Removal of Master Clump

1) Remove the screen. \See page 153 2) Remove 2 screws on the operation side. 3) Remove the bearing plate and spring. 4) Remove 2 screws on the anti-operation side to take out the bearing plate. 5) Remove the master clump. The master clump is attached to the base with the magnet.
Reinstallation IMPORTANT : Master clump Spring Screw
Screw Bearing plate
Adjust the master clump after installation. \See page 184
(3) Removal of Base Unit

1) Remove the master clump. 2) Remove 2 screws, and remove the base unit.
Screw Base unit Screw
154
chap.3
m Drum Section
(4) Removal of Outer Frame (Right) Unit

1) Remove the drum. 2) Remove 2 screws on the rail and 1 screw on the stay. 3) Remove 3 screws on the outer frame (right) unit and knob screw.
Reinstallation IMPORTANT : Do not forget to adjust the rail Rail left Rail right Screw Screws Stay
space after the rail is installed. \See page 185

Screw Outer frame (right) unit
Screws
4) Part the outer frame (right) unit a little and remove 2 connectors. 5) Remove the outer frame (right) unit.
Connector
Connector Outer frame (right) unit
155
chap.3
m Drum Section
(5) Removal of Outer Frame (Left) Assy

1) Remove the dram. 2) Remove the screw on the rail to take out the rail. 3) Remove the screw on the stay to remove the stay.
Reinstallation Screw IMPORTANT : Do not forget to adjust the rail
Stay
Rail left
space after the rail is installed. \See page 185
Rail right
Screws
4) Remove 4 screws.
Master clump lever Outer frame shaft Assy
Screws
5) Pull out the outer frame (left) assy with the master clump open.
Outer frame shaft assy
156
chap.3
m Drum Section
(6) Removal of Inner Frame

1) Remove the outer frame (right) unit. \See page 155 2) Loosen 2 set screws on the supporting plate, move the supporting plate in the direction of arrow until it stops and fix it with the screw.
Screws
Supporting plate
3) Pull out the inner frame (section inside the drum) in the direction of an arrow.
IMPORTANT : Be careful not to damage the drum
inside.
Reinstallation
Slide the supporting plate in the direction of arrow 1 so that the supporting plate roller, roller unit and roller are in contact with the inner surface of the flange right and tighten the roller with the screw, pressing the roller to the inner surface lightly.
Screws Roller Supporting plate
Roller unit
Roller
157
chap.3
m Drum Section
(7) Removal of Ink Pump

1) Remove the inner frame. \See page 157
Hose band Screw
2) Loosen the screw on the hose band to remove the hose.
Hose
3) Remove the screw to take out the link. 4) Remove 2 screw to take out the ink pump.
Screw Link Ink pump
Screws
(8) Removal of Ink Motor

Rotation plate Set screw
2) Cut the tie wrap. 3) Loosen the set screw to remove the rotation plate. 4) Remove 3 screws to take out the motor.
Screws
Motor
158
chap.3
m Drum Section
(9) Removal of Ink Detection PCB Unit

Toothed lock washer Screw Connector Screw
2) Pull out the connector. 3) Remove 2 screws to take out the ink detection PCB Unit.
IMPORTANT : The toothed lock washer is attached
to one of the screws. Be careful not to lose it.
Reinstallation IMPORTANT : Confirm that the detection needle is
vertical with the PCB Unit and does not contact anywhere, when installing the Ink detection PCB Unit.
Detection needle
Squeegee roller
Ink roller
159
Chapter 4
Standards / Adjustment
v Drum Driving Section ................................................176 (1) Adjusting the Stop Position .................................176 (2) Adjusting the Master Attachment / Detachment Position ..............................................177
z Scanner Section.........................................................162 (1) Adjusting the Timing Belt Tension .....................162 x Platemaking / Master Feed / Ejection Section.........163 Platemaking / Master Feed Section ......................163 (1) Adjusting the Timing Belt Tension .....................163 Master Ejection Section .........................................164 (1) Attaching the Spring ............................................164 (2) Adjusting the Timing Belt Tension .....................165 Master Clump opening/Closing Section ..............166 (1) Adjusting the Timing Belt Tension .....................166 (2) Positioning the Master Clump Opening / Closing Levers.....................................166 (3) Adjusting the A / B / C Modes..............................167
b Press Section ............................................................178 (1) Adjusting the Press Roll (P Roll) Sensor.............178 (2) Adjusting the Printing Area (Press OFF Timing) ...................................................179
n Paper Ejection Section .............................................180 (1) Adjusting the Paper Stripper Finger Clearance..................................................180 (2) Adjusting the Paper Stripper Finger Return Stopper..........................................181
c Paper Feed Section....................................................171 (1) Adjusting the Paper Separator Unit Clearance .....................................................171 (2) Adjusting the Paper Separation Pressure...........172 (3) Adjusting the Paper Feed Tray Upper Limit Sensor .............................................172 (4) Adjusting the Paper Feed Tray Lower Limit Switch .............................................173 (5) Adjusting the G Roll Escape Amount / Timing DP-21S .....................................174 (6) Adjusting the Printing Position Sensors .............175
m Drum Section .............................................................182 (1) Adjusting the Ink Amount ...................................182 (2) Adjusting the Squeegee Gap ................................183 (3) Adjusting the Master Clump ...............................184 (4) Adjusting the Master Clump Section ..................184 (5) Adjusting the Drum Rail Gap..............................185
160
, Electrical System .......................................................186 (1) Adjusting Reduction / Enlargement ....................186 1. Adjusting the Longitudinal R/E on the Platemaking Side ...................................186 2. Adjusting the Longitudinal R/E on the Reading Side...........................................186 (2) Reading Start Position .........................................187 1. Adjusting the Top End Reading Start Position .....................................................187 2. Adjusting the Lateral (Operation Side) Reading Start Position ......................................187 (3) Adjusting the Platemaking Start Position ..........188 1. When the Scanner Is in Use..............................188 2. When in Online..................................................188 (4) Adjusting the Document Reading Darkness.......189 1. Adjusting the White Level of the Document Darkness ..........................................189 2. Adjusting the Reading Darkness ......................190 (5) Adjusting of Printer Unit's Printing Speed.........191 1. Pre-stop Speed Adjustment...............................191 2. JOG Speed Adjustment .....................................191 3. Adjustment of Printing Speeds 1-3...................192 4. To Initialize Speed Settings ..............................192
. Option .........................................................................193 (1) Adjusting and Replacing the Upper / Lower Blade for the TAPE CLUSTER.................193
161
chap.4
z Scanner Section
zScanner Section
(1) Adjusting the Timing Belt Tension
NOTE : For removal of the ADF front cover.
\See page 122 Adjustment procedure 1) Use the set screw to adjust the belt's tension to about 700g.
Tension Set screw
700g
Timing belt
23S0048
162
chap.4
xPlatemaking / Master Feed / Ejection Section

Platemaking / Master Feed Section
NOTE : For removal of master feed unit.
\See page 138
Adjustment procedure 1) Use the set screw to adjust the belt's tension to about 1kg.
Set screw
Timing Belt 1kg
23S0108
163
chap.4

(1) Attaching the Spring
rSpring T (B)(3) L220mm E F A IMPORTANT : Set the hook on the spring B C eSpring T (B)(3) L220mm D A B C D E F : Rubber roller : Driving roller : Inverted roller : Driving roller : Inverted roller : Inverted roller
and crush it to prevent removing.
qSpring T (3) L90mm wSpring T (3) L104.9mm
1) Attaching the spring between A and B.

B A qSpring T (3) L90mm
2) Attaching the spring between B and C.
B wSpring T (3) L104.9mm
3) Attaching the spring between C, D and E.

E
C eSpring T (B)(3) L220mm
4) Attaching the spring between D, E and F.

F
D rSpring T (B)(3) L220mm
164
chap.4

NOTE : For removal of the master ejection box.
\See page 140
Adjustment procedure 1) Loosen the tensioning screw. 2) Use the tensioning screw to adjust the belt's tension with a force of 0.75kg applied to the tension shaft, as shown in the figure at right.
Tensioning screw Timing belt Tension
0.75kg
After adjustment
Function testing of roll-up motor
1) Access HELP mode H-18. HELP mode H-18 \ see p.258
For basic HELP mode procedures \See page 235
2) Press and hold down the "down" PRINTING SPEED ADJUSTMENT key. For as long as this key is held down, the roll-up motor will rotate in the reverse direction (counterclockwise), causing the rollers inside the master ejection box to rotate. 3) The motor will stop when the "down" PRINTING SPEED ADJUSTMENT key is released. 4) Press the STOP key. The HELP mode menu will reappear.
\ To exit the HELP mode: Turn the power switch to OFF. \ To select another HELP mode: Enter the desired HELP mode number using the numeric keys.
165
chap.4
Master Clump Opening/Closing Section

NOTE : For removal of master clump opening / closing unit. Tension Screws
\See page 142 Adjustment procedure 1) Loosen the tension set screw. 2) Use the set screw to adjust the belt's tension to about 1kg.
1kg
After Adjustment
IMPORTANT : Be sure to adjust the A/B/C mode
23S0079
after installation to the printer.
(2) Positioning the Master Clump Opening / Closing Levers

NOTE : For removal of master clump opening / closing unit.
Position hole
\See page 142

Master feed master clump opening/closing lever Positioning hole
23S0081
1. Paper feed master clump opening/closing lever When tensioning the timing belt, ensure that the sub frame is positioned so that the upper surface of the master clump opening/closing lever is aligned (to within 0.5mm) with the rim of the positioning hole.
Paper feed side Sub-frame
Positioning hole Aligned (to within 0.5mm) Master feed master clump opening/closing lever
23S0081
2. Paper ejection master clump opening/closing lever When tensioning the timing belt, ensure that the master clump opening/closing lever is co-centered with the sub-frame's positioning holes. After Adjustment
IMPORTANT : Be sure to adjust the A/B/C mode
Paper ejection side Positioning hole Main frame R
after installation to the printer. 166

23S0082
chap.4
(3) Adjusting the A / B / C Mode

NOTE : For description of operation.
\See page 81
1. Adjustment for B mode

Adjustment procedure 1) Remove the drum from the machine body. 2) Access HELP mode H-20. HELP mode H-20 \ see p.260 For basic HELP mode procedures. \See page 235
When drum is removed from main body (A mode)
3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clump open/close lever moves into the "more open than B mode (toward C mode) position" (see right). 4) Turn the power off, then on again. The master clump switch lever will move into the B mode position and stop there. 5) Turn off the power, and install the drum to the machine body.
More open than B mode (toward C mode) position C mode B mode
uShift
6) Open the plate ejection box. Then press the JOG switch (drum rotator switch) to move the master clump to a position in front of the open/close lever, and stop it there.
yStop in front of lever
WARNING
Do not touch the drum or rolls when operating the JOG switch. Do not put your hands or fingers inside the machine during operation. They could be caught up or crushed in the machinery, resulting in injury.
7) Move the master clump, paying attention to the clearance at the same time.
167
chap.4
Standard value
Check that the clearance between the master clump lever and master clump open/close lever is within the range given below.
Item Clearance between master clump lever and master clump open/close lever Standard value 1.0 - 1.5mm
1.0~1.5mm Master clump lever Master clump open/close lever
If the clearance it outside the standard range: 1) Turn the fixing screw indicated to move the B mode shade plate and thereby adjust the clearance.
A / C mode sensor (PS3) B mode shade plate
B mode sensor (PS4) Fixing screw
Open
Close
After adjustment Follow the procedure below to return to the previous state. 1) Remove the drum. 2) Access HELP mode H-20. HELP mode H-20 \ see p.260 For basic HELP mode procedures. \See page 235 A mode 3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clump open/close lever moves into the A mode position (see right). 4) Turn off the power, and install the drum to the machine body.
168
chap.4
2. Adjustment for A and C modes

Before adjustment
IMPORTANT : A and C mode adjustment must be
carried out AFTER B mode adjustment has been completed. Adjustment procedure 1) Remove the drum from the machine body. 2) Access HELP mode H-20. HELP mode H-20 \ see p.260 For basic HELP mode procedures. \See page 235
When drum is removed from main body (A mode)
3) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clump open/close lever moves into the "more open than B mode (toward C mode) position" (see right). 4) Turn the power off, then on again. The master clump open/close lever will move into the B mode position and stop there. 5) Turn off the power, and install the drum to the machine body. 6) Access HELP mode H-09. HELP mode H-09 \ see p.248
More open than B mode (toward C mode) position C mode B mode
Stopping drum in master detachment position
7) Press the PRINT key to move the drum to the master detachment position, and stop it there. 8) Use HELP20 to move the master clump open/ close lever to the C mode position.
IMPORTANT : Do not move the master clump
open/close lever towards the A mode position from the B mode position. Doing so will break the master clump. 9) Open the scanner unit.
0.5-1.0mm
169
chap.4
Standard value
Check that the clearance between the master ejection box's rubber roller and the master clump plate is within the range given below. Rubber roller
Item Clearance between master ejection box's rubber roller and master clump plate Standard value
0.5~1.0mm
Master clump plate

0.5 - 1.0mm
If the clearance is outside the standard range 1) Turn the fixing screw indicated to move the A/C mode shade plate and thereby adjust the clearance. This operation adjusts the clearance for both the A and C modes.
IMPORTANT :
A / C mode shade plate A mode sensor (PS3)
Do not press the master clump against the rubber roller.
Fixing screw B mode sensor (PS4)
Open Close
After adjustment Follow the procedure below to return to the previous state. 1) Turn the power off, then on again. The master clump open/close lever will move into the B mode position and stop there. 2) Remove the drum. 3) Access HELP mode H-20. HELP mode H-20 \ see p.260
A mode
4) Press and hold down the "up" PRINTING SPEED ADJUSTMENT key, until the master clump open/close lever moves into the A mode position (see right). 5) Turn off the power, and install the drum to the machine body.
170
chap.4
cPaper Feed Section

(1) Adjusting the Paper Separator Unit Clearance
NOTE : For description of operation .
\See page 90
For removal of paper separator unit .
\See page 145
Adjustment procedure When the paper separator unit is installed, use the adjustment bolt to adjust the unit so that it moves in direction q without sticking, and moves smoothly in direction w. Tighten the bolt's nut to fix the unit in the adjusted position.
q
Paper separator unit
w Nut
23S0106
171
chap.4
(2) Adjusting the Paper Separation Pressure

\See page 90
For removal .
\See page 145 Adjustment procedure 1) Apply a spring balance as shown at right, then turn the separation pressure adjust screw so that the balance reads 150-160g. Turning the screw clockwise increases the pressure. Turning the screw counterclockwise decreases the pressure.
Spring balance 150-160g
Paper separation pressure adjust screw
43SH0403
(3) Adjusting the Paper Feed Tray Upper Limit Sensor

\See page 94 Adjustment procedure 1) Insert a 1mm thick strip of material between the paper feed roller and the paper feed inlet. 2) Loosen the 2 screws indicated, then adjust the sensor's position so that the bottom surface of the paper feed shaft lever is at the center of the sensor. 3) After adjustment, tighten the screws.
Position bottom surface at sensor's center
Screw Paper feed tray upper limit sensor Screw 1mm thick strip
23S0225
172
chap.4
(4) Adjusting the Paper Feed Tray Lower Limit Switch

\See page 95
For removal.
\See page 144
Adjustment method 1) Access HELP mode H-02. HELP mode H-02 \ see p.241 For the basic procedure for accessing HELP modes: \See page 235
2) Press and hold down the "down" PRINTING SPEED ADJUSTMENT key until the paper feed tray is at its lowermost position. The elevator motor will run (i.e. the paper feed tray will descend) for as long as the key is held down. 3) Check that the dimension indicated in the figure at right conforms to the value shown below.
Standard value
Item Paper feed tray clearance in lower limit position Standard value 14mm
14mm
23S0109
If the feed length is not the standard value 1) Loosen the screws, then adjust the lower limit switch to a position that yields the standard clearance value. cMoving the sensor in the direction shifts the lowermost position downward. dMoving the sensor in the direction shifts the lowermost position upward. 2) After adjustment, tighten the screws.
Paper feed tray lower limit switch Level position Screws
23S0107
173
chap.4
(5) Adjusting the G Roll Escape Amount / Timing DP-21S

Adjustment procedure 1) Turn the main motor shaft by hand, to move the escape cam. Stop turning when the bottom of the escape cam reaches the bearing side of the escape lever, so that the cam stops in that position. 2) Loosen the eccentric shaft fixing screw. Then turn the eccentric shaft to adjust the escape amount.
NOTE : For description of operation. Peek through the inspection hole. Bearing Escape lever
20.2mm Eccentric shaft Screw Escape cam

23S0228
\See page 88
Standard value
Item Clearance between escape lever's bearing and escape cam's bolt
Standard value 20.2mm
174
chap.4
(6) Adjusting the Printing Position Sensors

\See page 91
1. Central sensor Adjustment procedure 1) To adjust the sensor's position, position the screws of the sensor bracket's rectangular holes in the center of those holes, and fix the screws in that position.
Screw Center sensor
Center
Sensor bracket
Center
Screw
23S0229
2. Limit sensor Adjustment procedure 1) Position the screws of the sensor bracket's rectangular holes in the center of those holes, and fix the screws in that position. 2) Loosen the limit sensor shade plate fixing screw. Then adjust the distance between the centerline of the central sensor and the edge of the central sensor shade plate to 20 1mm.
Top limit
Screw
Center
Sensor bracket
Center
Screw Limit sensor

23S0230
Bottom limit
Screw
Center
20mm
Center
Screw Limit sensor

23S0231
175
chap.4
v Drum Drive Unit
vDrum Driving Section

(1) Adjusting the Stop Position
Before adjustment
IMPORTANT :
Adjusting the the drum position must be performed AFTER printing speed adjustment is complete. \See page 191
Adjustment procedure 1) Press and hold down the JOG switch (DRUM ROTATOR switch). Release the switch when a "beep" tone sounds and the drum stops.
WARNING
Stopper
Groove
\See page 98
Standard position The stop position is correctly adjusted when the groove in the drum flange is aligned with the stopper. If the drum is not adjusted to the standard stop position: Adjust the position of the drum home position / JAM detection sensor so that the stopper fits smoothly into the groove when the drum is pulled out. [ Moving the sensor in this direction makes stopping occur later. \ Moving the sensor in this direction makes stopping occur earlier.
JOG switch (DRUM ROTATOR switch)
Screws
Drum stop detection edge
23S0232
176
chap.4
v Drum Drive Unit
(2) Adjusting the Master Attachment/Detachment Position

NOTE : For description of operation. Master attachment position
\See page 99
Master detachment position
1. Master detachment position The correct position for stopping of the drum (position for master detachment) is when the center axis of the master clump open/close arm and the center axis of the master clump open/ close lever are aligned in a straight line. Adjust so that the offset of the alignment of these two center axes is 1mm (gauge this value visually).
Open/close lever
Open/close arm
+ -1mm
23S0234
Adjustment procedure 1) Access HELP mode H-09, the drum position check mode. HELP mode H-09 \ see p.248
Master attachment/det achment position edge

23S0235
Item Offset in alignment of center axes of master clump open/close arm and master clump open/close lever
Standard value 1mm
Open/close arm
+ -1mm
4) Loosen the screws indicated, turn the master attachment/detachment sensor shade plate a little in the direction of the arrows, and provisionally tighten the screws. 5) Repeat step 2), and check the center axis alignment offset. 6) If necessary, repeat steps 2) through 5) until the center axis alignment offset is within 1mm. 7) Properly tighten the screws, and check 6) again. 2. Master attachment position Perform adjustment of master attachment position at the same time as that of master detachment position. Adjust both positions to an accuracy of 1mm.
Open/close lever
23S0236
Screws
Advances the stop position Sets back the stop position

23S0233
177
chap.4
b Press Section
bPress Section
(1) Adjusting the of Press Roll (P Roll) Sensor
\See page 105
Adjustment procedure 1) Loosen the screw indicated. Then move the sensor bracket up/down to adjust the press roll so that when it is pushed down to the lowest position by the cam, the distance between the bottom of its sensor and the end of the bracket is about 1mm.
Bracket About 1mm P roll sensor Bracket Screws

23S0238
178
chap.4
b Press Section
(2) Adjusting the Printing Area (Press OFF Timing)

\See page 103

Rear end of opening
20mm
Adjustment procedure 1) Make a mark on the end surface of the drum flange, in a position 20mm forward (in the direction of the forward end) from the rear end of the drum's opening(hole section). 2) With the press roll activated, turn the main motor shaft by hand, and stop turning when the press roll starts to descend (move in the direction of the arrow).
Make mark here
Drum unit
Press roll
Main motor shaft
23S0237
Standard value Open the front cover, and check whether the center of the press roll is aligned with the mark made in step 1).
Mark
Item Alignment of mark on flange end and center of press roll Standard value 2mm
Drum flange Press roll

23S0246
If the alignment is not correct: 1) Loosen the 2 hex bolts indicated. 2) Loosen the adjustment collar (eccentric) fixing screw. 3) Turn the adjustment collar (eccentric) to move the flange and adjust the alignment. Moving the flange upward makes turning off of the press occur later \ thereby making the printing range longer Moving the flange downward makes turning off of the press occur earlier \ thereby making the printing range shorter
Adjust collar
Hex bolts
Screw
23S0239
179
chap.4
nPaper Ejection Section

(1) Adjusting the Paper Stripper Finger Clearance
\See page 107

Lever
Pinch lever
Adjustment procedure 1) With the pinch lever raised up, turn the main motor shaft. Stop turning when the lever's roller is positioned at the bottom of the paper stripper finger cam.
Roller
Main motor shaft

23S0240
Standard value Check that the clearance between the drum surface and the paper stripper finger conforms to the value shown below.
Item Clearance between drum surface and tip of paper stripper finger Standard value about 0.5mm
Drum surface
About 0.5mm
If the clearance is not the standard value: 1) Loosen the screw indicated and use the stopper to adjust the clearance to the standard value. Then retighten the screws. After adjustment:
IMPORTANT :

23S0247
Screw
After adjustment, press the JOG switch (DRUM ROTATOR switch) to return the drum to its home position.
WARNING
23S0241
Do not touch the drum or rolls when operating the JOG switch. Do not put your hands or fingers inside the machine during operation. They could be caught up or crushed in the machinery, resulting in injury. 180
chap.4
(2) Adjusting the Paper Stripper Finger Return Stopper

Adjustment procedure 1) Turn the main motor shaft by hand until a clearance is opened up between the pinch lever and the bracket.
Clearance
Bracket
Pinch lever
23S0242
Standard value Check that the clearance between the lever and the paper stripper finger return stopper conforms to the value shown below.
Lever about 1mm
Item Clearance between lever and paper stripper finger return stopper
Standard value about 1mm Screws Paper stripper finger return stopper
23S0243
If the clearance is not the standard value: Loosen the 2 screws indicated and use the stopper to adjust the clearance to the standard value. Then retighten the screws. After adjustment:
IMPORTANT :
After adjustment, press the JOG switch (DRUM ROTATOR switch) to return the drum to its home position.
WARNING
181
chap.4
m Drum Section
mDrum Section
(1) Adjusting the Ink Amount
Adjusting the ink adjusting knob
NOTE : For removal. Ink adjusting knob on the operation side
\See page 153
Ink adjusting knob on the rear side
Adjustment procedure 1) When printed too dark or too light on the operation side: Too dark: switch in the (-) direction (3 settings) Too light: switch in the (+) direction (3 settings)
Ink adjusting knob on the operation side (standard position) Too dark
Too light
Do not loosen set screw
2) When printed too dark or too light on the rear side: Too dark: switch in the (-) direction (3 settings) Too light: switch in the (+) direction (3 settings) 3) When printed too dark or too light on the entire surface: Adjust the above 1) and 2) at the same time.
IMPORTANT : There are 7 settings, standard and
Ink adjusting knob on the rear side (standard position) Too dark
Too light
Do not loosen set screw
3 settings to adjust the printing darkness. Print more than ten sheets every time the printing darkness is switched by one setting until the most desirable printing darkness is obtained. Repeat the above procedures until the most desirable printing darkness is obtained. 182
chap.4
m Drum Section
(2) Adjusting the Squeegee Gap

NOTE : For removal. Squeegee
Ink roller
\See page 153
Adjustment procedure The gap between the squeegee and the ink roller is adjusted as shown in the figure when the ink amount is based on the standards. If the ink amount does not meet the standards, adjust it as follows:Standard value
Item Clearance between squeegee and ink roller Standard value 0.03mm-0.04mm
Gap
0.03 0.04mm
Ink roller
0.03 Squeegee 0.04mm
0.03 0.04mm
If the clearance is not the standard value 1) 2 set screws 1 are used in one place. Remove one set screw 1 and loosen the other one. Perform the same operation for both sides. Be careful not to lose the removed set screws. 2) Loosen set screws 2 on both sides. 3) Adjust the gap with the adjusting screws on both sides so that the space on both sides meets the standards.
Operation side
Set screw 2 Ink adjusting knob
Adjusting screw Set screw 1
Rear side After adjustment 1) Tighten set screw 2. 2) Tighten set screw 1. 3) Check the gap again after the ink amount adjusting knob is moved several times in the direction + or -. 4) If the gap is proper, attach set screw 1 and tighten it to fix.
Adjusting screw Set screw 1
Set screw 2 Ink adjusting knob
183
chap.4
m Drum Section
(3) Adjusting the Master Clump

NOTE : For removal. Set screws Set screws (for adjustment) shaft
\See page 154
When the master clump parallelism is not proper, the master creases. When the master clump is not flat, the master is easily removed and creases. * Adjust the master clump with the set screw on the operation side.
Operation side Lever shaft Clump plate
1. Adjusting the clump parallelism

Adjustment procedure 1) Loosen the set screws on the clump plate and shaft to adjust the parallelism.
IMPORTANT : Loosen the set screw on the Clump plate
Master 20mm 20mm
Master 20mm
Master
operation side to adjust. But do not loosen the set screw on the lever shaft.
Clump plate
2. Adjusting the clump flatness

Adjustment procedure 1) Cut the master, leaving 20mm wide piece at three places, both sides and center. Have the clump plate grip the three sections. 2) When the resistance for pulling the master out is not stable, rotate the clump screw to adjust.
Rubber magnet
Torsion
(4) Adjusting the Master Clump Section

Adjustment procedure 1) Adjust with HELP mode 29 so that the clump amount of the master (A section in the figure) is 0~3mm with the master attached. HELP mode H-29 \ see p.268 2) After HELP 29 adjustment, press the master set switch and perform master set movement once. (Be sure to remove all paper scraps.) Then perform platemaking, and check the gripper margin.
Master clump
184
chap.4
m Drum Section
(5) Adjusting the Drum Rail Gap

1. Operation side
Adjustment procedure 1) Attach the drum to the main body. 2) Loosen the set screw on the rail to adjust so that the gap between the rail (both sides) and the roller on the operation side is about 0.3mm. 3) Tighten the set screw to fix the rail.
Screw
Rail unit left
Rail unit right
Screw
0.3mm Guide rail left
0.3mm Guide rail right

23S0244
2. Rear side
Adjustment procedure 1) Open the rear cover on the main body. 2) Loosen the screws on the rail to adjust so that the gap between the roller on the rear side and the rail right / left unit is about 0.3mm. 3) Tighten the screw to fix the rail.
Screw
Rail unit left
Rail unit right
Screw
0.3mm Guide rail left
0.3mm Guide rail right

23S0245
185
chap.4
, Electrical system
,Electrical system
(1) Adjusting Reduction / Enlargement
1. Adjusting the Longitudinal R / E on the Platemaking Side
Adjustment procedure 1) Set the HELP mode. Turn the power on with the PRINTING SPEED ADJUSTMENT keys and held down. 2) Set to H-30 (Test pattern printing mode). Press the PRINT key with the 3 and 0 keys held HELP mode H-30 \ see p.269 down. 3) Set the plate darkness to NORMAL , perform platemaking and print paper*. No need to place the document. *DP-23S : print B4 paper *DP-21S/21L : print A4 paper Standard values: Check that A section of the printed test pattern is 200 0.5mm. If the clearance is not the standard value: 1) If not, adjust with the H-22. HELP mode H-22 \ see p.261
Test pattern 3
2. Adjusting the Longitudinal R / E on the Reading Side

Before adjustment
IMPORTANT : Adjust the longitudinal R / E on the
reading side after the longitudinal R / E on the platemaking side. Adjustment procedure 1) Prepare a basic document as shown in the figure. Draw a line (main-scanning direction) at the position 30mm from the top end of the paper* and at the position 200mm from the above line. *DP-23S : print B4 paper *DP-21S/21L : print A4 paper 2) Place the document on the document table to perform platemaking and printing. Standard values: Compare the size of A section of the printed image with that of the basic document. Check that the difference of the size is 2.0 mm. If the clearance is not the standard value: 1) If not, adjust with the H-24. HELP mode H-24 \ see p.263 186
23S0312
Center of the paper
chap.4
, Electrical system
(2) Reading Start Position

1. Adjusting the Top End Reading Start Position
Adjustment procedure 1) Mark with 1mm interval up to 5mm from the top end of the paper to prepare a test document. 2) Perform platemaking and printing to the same size and to two printouts. 3) Adjust with the HELP35 so that the image of the second printout is printed with 3mm margin left. HELP mode H-35 \ see p.273
23S0313
Document
Print 2 - 3mm
2 printouts Mark with 1mm interval from the top end of the document
2. Adjusting the Lateral (Operation Side) Reading Start Position

Adjustment procedure 1) Make a standard document (as shown in the figure) from a sheet of paper*. Draw a 100mm line at the position 30mm from the right end and from the top end of the paper*. *DP-23S : print B4 paper *DP-21S/21L : print A4 paper
Standard document
100mm 30mm
23S0314
2) Compare the printed image with the basic document. Check the difference between the straight lines in the main-scanning direction.
Printing paper
Print ejection direction
Document
3) Adjust with the HELP H-36 so that L1 - L2 3mm. HELP mode H-36 \ see p.274
Mark this corner with each other Document basic line
Adjusting direction L1<L2 : Backward L1<L2 : Toward you
Basic line of the printed sample
L2
L1
23S0315
187
chap.4
, Electrical system
(3) Adjusting the Platemaking Start Position

1. When the Scanner Is in Use Before adjustment
IMPORTANT :
Adjust the platemaking start position with the scanner in use after the printing position sensor \See page 175 , master attachment / detachment position \See page 177 and top end reading start position \See page 187 are adjusted. Adjustment procedure 1) Set the printing position (top and bottom direction) to the standard. 2) Draw a line at the position 30mm from the top end of the document and prepare a basic document as shown in the figure. 3) Compare the processed image with the basic document. Check the difference of the lines inthe sub-scanning direction. 4) Adjust with the HELP mode, H-37 so that L1 - L2 3mm. HELP mode H-37 \ see p.275
Printing paper
Standard document
Draw a line at the position 30mm from the top end of the document
23S0316
Print ejection direction
Adjusting direction L1<L2 : Upward L1>L2 : Downward
Document
Mark this corner with each other
Basic line of the printed sample
Document basic line
L1 L2
23S0317
2. When in Online Before adjustment

IMPORTANT :
Adjust the platemaking start position when in online after the printing position sensor \See page 175 and master attachment / detachment position \See page 177 are adjusted. Adjustment procedure 1) Perform platemaking and printing of the online test pattern. Adjust with the HELP mode, H-16 so that the basic line is positioned 3mm from the top end of the paper. HELP mode H-16 \ see p.257
188
chap.4
, Electrical system
(4) Adjusting the Document Reading Darkness

\See page 56
1. Adjusting the White Level of the Document Darkness The basic darkness of the document (lightness of the white section of the document = white level) is detected by reading the document darkness. If the white level is not proper, printed surface gets dirty or the light section of the document is not processed for platemaking.
In the normal state
When the white level is too high:

the section is printed dirty
Adjusting the White Level 1) Call the HELP mode. Take the following procedures for adjustment:When the white level is too low:
1. Text mode: H-33 HELP mode H-33 \ see p.272 2. Photograph mode: H-26 HELP mode H-26 \ see p.265
the section is not processed for platemaking
2) Input the correction value on the keypad, "0" or "1". When the processed document gets dirty : "0 1 1 1" The white level is corrected down.
HELP mode H-33/26 display
A: 0
Sign flag
B:1 C:1 D:1

Correction amount display
When the thin section of the document is not processed for platemaking : "1 1 1 1" The white level is corrected up.
A: 1
Sign flag
B:1 C:1 D:1

3) Press the = value.
key to memorize the correction
4) Perform platemaking and printing to check the darkness.
189
chap.4
, Electrical system
2. Adjusting the Reading Darkness Adjustment procedure Adjust the document reading darkness in platemaking as follows: 1) Help mode Text mode : H-50 HELP mode H-50 \ see p.281 Photograph mode : H-23 HELP mode H-23 \ see p.262 2) Input the correction value on the keypad, "1" or "0" (Sign flag / Collection amount display). HELP mode H-50/23 display
A:1 B:1 C:1 D:1

Sign flag Correction amount display
3) Press the = key to memorize the correction value 4) Perform platemaking and printing to check the darkness. When adjusted with the H-23 by one stage, the standard position on the control panel changes to 3/8 stage as follows : Adjusting the platemaking darkness on the control panel dark H-50, H-23: [0001] dark Normal light light light
23S0318
dark
H-50, H-23: [0001]
Normal
190
chap.4
, Electrical system
(5) Adjusting of Printer Unit's Printing Speed

1. Pre-stop Speed Adjustment Adjustment procedure 1) Access HELP mode H-01. HELP mode H-01 \ see p.238 For basic HELP mode procedures. \See page 235 HELP mode H-01 display
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select PHOTOGRAPH. 3) Check the speed value displayed. The value should be 4-6rpm. If the value is not correct: Turn the main motor PCB unit's VR1 to adjust the displayed value to within the correct range. 4) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear.
111
r pm
Pre-stop speed
Main motor PCB unit

VR1
23S0283
2. JOG Speed Adjustment Adjustment procedure 1) Access HELP mode H-01.
HELP mode H-01 \ see p.238 \See page 235 HELP mode H-01 display
For basic HELP mode procedures.
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select TEXT/PHOTOGRAPH. 3) Check the speed value displayed. The value should be 16rpm. If the value is not correct: Turn the main motor PCB unit's VR 2 to adjust the displayed value to the correct value. 4) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear.
111
r pm
JOG speed
Main motor PCB unit

VR2
23S0284
191
chap.4
, Electrical system
3. Adjustment of Printing Speeds 3 Adjustment procedure 1) Access HELP mode H-01. HELP mode H-01 \ see p.238 For basic HELP mode procedures. \See page 235
2) Press the DOCUMENT MODE SWITCH key repeatedly, to select TEXT. 3) Use the "down" PRINTING SPEED ADJUSTMENT key to select SPEED 1. 4) Check the speed value displayed. The value should be 60rpm.
HELP mode H-01 display
111
r pm
Printing speed
If the value is not correct: Use the FUNCTION SWITCH and SELECT keys to adjust the displayed value to the correct value. 5) If desired, set the other printing speeds (2,3) by repeating steps 2) through 4) , and selecting the desired speed in step 2). 6) (If setting the other speeds:) Check the speed values displayed. The values should be:
Speed 2 ... 80rpm Speed 3 ... 120rpm
If the values are not correct: Use the FUNCTION SWITCH and SELECT keys to adjust the displayed values to the correct values. 7) Press the STOP key. The new (adjusted) value will be memorized, and the HELP mode menu will reappear. 4. To Initialize Speed Settings: HELP mode H-01 \ see p.239 1) Access HELP mode H-01. For basic HELP mode procedures. \See page 235
HELP mode H-01 display
HELP
SELECT
01
2) Press the [=] and CLEAR C key. The settings will be initialized. 3) Press the STOP key. The HELP mode menu will reappear.
Mode number flashes
NOTE : After initialization, new speed values must be set.
192
chap.4
. Option
.Option
(1) Adjusting and Replacing the Upper / Lower Blade for the TAPE CLUSTER
Adjustment procedure 1) When the solenoid is pulled manually, adjust the solenoid position up and down so that the upper blade edge is positioned 1.5 - 2.0 mm lower than the lower blade. 2) At the same time, adjust the space with the adjusting washer so that the space of the blades is about 0.5 mm when seen from the top.
Lower blade
Upper blade
Upper blade 1.5-2mm Lower blade
Solenoid
43SH0414
193
MEMO
194
Chapter 5
Installation
z DUPRINTER Installation Instructions .....................196 1. Before Installation ..................................................196 2. Installation Instructions.........................................196 (1) Unpacking Checks ............................................196 (2) Assembly ...........................................................197 (3) Power Switch ON ..............................................199 (4) Setting the Master Roll ....................................200 (5) Preparation of Drum .........................................202 (6) Setting the Ink Pack .........................................204 (7) Supplying Ink and Adjusting Ink Amount ......205 (8) If Option are Installed ......................................205
195
chap.5
z DUPRINTER Installation Instructions
zDUPRINTER Installation Instructions

1. Before Installation :
Safety precautions
The precautions below are vital for safety and must be taken.
2. Installation Instructions
(1) Unpacking Checks
q Packages for 1 complete DUPRINTER: DP-23S 1 printer unit package (product name: DP-23S) DP-21S 1 printer unit package (product name: DP-21S)
WARNING
Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected. aUse of any other power cord could result in imperfect grounding. If grounding is imperfect and electrical leakage occurs, fire or electric shock could result. Do not use a source voltage other than that specified. Do not connect multiple loads to a single outlet. Fire or electrical shock can result. Do not place the machine in an unstable position, such as on an unsteady support or sloping area. If the machine drops or falls over, a person could get injured. Do not place the machine in a humid or dusty area. Fire or electrical shock can result.
Check that the above 2 packages are present.
w Unpack the package.

IMPORTANT : Carry out unpacking in a place that
is safe for the work.
e Contents checks for each package. Check that the packages have the contents listed below. Printer unit package
Item Printer unit proper Installation instructions Operation Manual Warranty Master ejection core Power cord Document Tray Print Tray Quantity 1 1 1 1 1 1 1 1
If the optional printer stand is used, install it now by referring to the instructions on the following page.
If the optional printer stand is used: When the DUPRINTER is installed to the printer stand, lock the casters. Otherwise the equipment could move or fall over, causing injury. To move the equipment, push on the printer stand. Pushing on the DUPRINTER is dangerous and could make the equipment fall over. 196
\See page 198
chap.5
(2) Assembly
(1) Assembly of DUPRINTER q Pull out the printer unit's 4 handles. Then lift the printer unit up by its handles and place it in the installation location.
t Attach the print tray, by fitting it into the slots in the DUPRINTER's top section.
Slot in top section
CAUTION
To lift the printer unit, hold it by its handles ONLY. Lifting of the printer unit should be performed by 2 or more persons, not by 1 person alone. Place the printer unit on a flat, level surface.
Print tray
23S0110
Pull out
Handles Pull out
Handles
23S0012
w Push the 4 handles back in. e Remove all the remaining fixing tape. r Attach the Document Tray to the DUPRINTER.
Document tray
23S0013
197
chap.5
Using the optional printer stand q Unpacking Check. 2Check that the printer stand unit package is present. w Unpack the printer stand unit package.
IMPORTANT : Carry out unpacking and assembly
!0 Remove all the remaining fixing tape. !1 Attach the Document Tray to DUPRINTER.
Document Tray
the
in a place that is safe for the work. e Check that the package has the contents listed below.
Item Quantity 1
Printer stand unit
* Check the unit's casters for abnormality. r Assemble the printer stand unit. t Place the printer stand unit on a flat, level surface. y Lock the printer stand unit's casters. u Pull out the printer unit's 4 handles.
23S0023
!2 Attach the print tray, by fitting it into the slots in the DUPRINTER's bottom section.
CAUTION
To lift the printer unit, hold it by its handles ONLY. Lifting of the printer unit should be performed by 2 or more persons, not by 1 person alone.
Slot in bottom section
i Lift up the printer unit by its handles, and mount it onto the printer stand unit so that its rubber feet mate into the recesses in the printer stand.
Print Tray
23S0111
Handle
Handle
Pull out
Runner feet
Recesses
Recesses
23S0027
o Push the 4 handles back in.
198
chap.5
(3) Power Switch ON

q Make sure that the power switch is OFF. w Insert the plug on one end of the power cord (one of the accessories) into the DUPRINTER's power inlet.
230V AC model
WARNING
Connect the DUPRINTER to an outlet providing a 50Hz, 8A power supply of at least 230V. Insert the power cord's plug correctly into the outlet, so that electrical connection is effected completely. Position the DUPRINTER close to the power outlet. Do not connect multiple loads to a single outlet. If use of an extension cord is necessary: Extension cord should be of at least 250V, 8A specification, conform to standard, and not exceed 5m in length. The power cord should never be stepped on, or crushed between objects. If it is, accidents could
Power inlet
Power cord
23S0010
result.
e Insert the plug on the other end of the power cord into the power outlet.
120V AC model
r Turn the power switch ON. t Check the liquid crystal display on the operation panel. The display should function normally.
WARNING
Connect the DUPRINTER to an outlet providing a 60Hz, 15A power supply of at least 120V. Insert the power cord's plug correctly into the outlet, so that electrical connection is effected completely. Position the DUPRINTER close to the power outlet. Do not connect multiple loads to a single outlet. If use of an extension cord is necessary: Extension cord should be of at least 130V, 15A specification, conform to standard, and not exceed 5m in length. The power cord should never be stepped on, or crushed between objects. If it is, accidents could result.
199
chap.5
(4) Setting the Master Roll

q Open the document receiving tray.
r Pull the lever, and open the master cover.

Master cover
Lever
23S0004
t Pull out the master, and pass it under the bar.

23S0001
w Pull the new master roll out of its bag, then insert it into the machine, making sure that its seal is correctly oriented.
Pay attention to orientation Master roll
Warning Label 1
Bar
23S0005
WARNING
Do not remove the cover affixed with
23S0002
e Peel off the seal. (First make sure that the end of the roll with the green line is at the control panel side.)
Warning Label 1. Personnel can get injured by the movable cutter installed inside.
Green line
y Push in the master, aligned with the set line, until the master's leading edge contacts the interior surface.
SET LINE
Seal
23S0003
23S0006
200
chap.5
u Close the master cover.

Master cover
23S0007
i Push the master set lever.

Master set lever
23S0008
o Gently close the document receiving tray.
23S0009
201
chap.5
(5) Preparation of Drum

q Press the jog switch (drum rotator switch). Hold down until the drum stops with a beep.
r Grip the upper drum shaft with your other hand, and pull the drum out toward you while slightly lifting the near end of the drum.
CAUTION WARNING
Do not touch the drum or rollers when you operate the jog switch. Do not put hands inside machine while it is operating. Hands could get caught up or crushed.
Upper drum shaft
Hold the drum level and place it on a flat, solid surface. The stainless screen does not return to the original state once it is folded. Be careful to handle the screen.
Jog switch
e
23S0014
23S0017
w Open the front cover toward you.
t Move the lever with a hand to open and close the master clump once or twice.
Master clump Front cover
23S0018 23S0015
e Lift up the drum securing lever. While lifting the lever up, pull out the drum handle toward you, pulling it straight out until it stops.
y Hold the drum level and place the drum guide roller onto the rail in the machine.
Drum Roller
Drum securing lever
Rail
23S0019
23S0016
202
chap.5
u Let go of the handle far end of drum, and push the drum in about 10 cm while slightly lifting the near end of the drum.
!1 Close the front cover.
Front cover
23S0023
23S0020
i Hold the drum level and push it in gently until it stops. o Lift the drum securing lever toward you while pushing the drum in.
!2 Press the jog switch (drum rotator switch). Continue pushing until the drum stops with a beep.
WARNING
Do NOT touch the drum or rollers when you operate the jog switch. Do NOT put hands inside machine while it is operating. Hands could get caught up or crushed.
Drum securing lever
23S0021
!0 Push down the securing lever tightly with the drum inside the machine.
Jog switch
23S0014
23S0022
203
chap.5
(6) Setting the Ink Pack

q Open the front cover.
Front cover
"U" groove of holder
t Push the ink pack to the set line on the ink pack.
23S0015
w Hold the ink pack holder release lever and pull it toward you.
Holder release lever
Set line
23S0024
y Push the side of the holder in with the palm of your hand.
e Twist open the cap of the new ink pack.
CAUTION
Do not leave an uncapped INK PACK for a
period longer than necessary.

23S0025
Ink pack
u Close the front cover.
Front cover
r Insert the ink pack so that the groove on the LIP fits into the "U" groove of the holder.
23S0026
Holder Holder
Ink pack
Ink pack
204
chap.5
(7) Supplying Ink and Adjusting Ink Amount

1. Supplying Ink
q Invoke the HELP mode. While holding down the PRINTING SPEED ADJUSTMENT keys and simultaneously, turn the power on. w Supply ink using HELP04. Enter <0> <4> from the keypad and then press the PRINT key. Drum will begin to rotate while the ink pump starts operation.After completion of supplying ink, drum will stop rotating with continuous beep sounds. In general, it takes approx.30 seconds to supply ink. e Turn the power OFF and then ON again. r Perform platemaking and printing of the document. For more information, refer to "Platemaking and printing procedure" in the Instruction Manual. The image will be light since ink is not fully spread over the drum surface. It is not a trouble. Continuously print approx.20 sheets.
e When the whole area of paper is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on both sides in the " 4" or "3" direction respectively (3 steps).
Setscrew Never loosen!
Ink Amount Adjustment Knob on the near side (Standard Position)
Setscrew Never loosen!
Ink Amount Adjustment Knob on the far side (Standard Position)
IMPORTANT :
IMPORTANT : The Ink Amount Adjustment Knob
t Once ink is fully spread, check the printed image.If the density varies between the near and far areas of paper, make adjustment according to the "Adjusting Ink Amount".
has a total of 7 positions : 3 positions for each of "4" and "3" directions as well as a standard position.When adjusting the image density, you should print the image on dozens of sheets to stabilize the density every time you change it by every step. Repeat the above steps until you get desired print density.
2. Adjusting Ink Amount

q When the near area is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on the near side in the " 4 " or " 3 " direction respectively (3 steps). w When the far area is darker or lighter, turn stepwise the Ink Amount Adjustment Knob on the far side in the " 4 " or " 3 " direction respectively (3 steps).
(8) If Options are Installed

Optional equipment should be installed AFTER the machine itself has been installed and test-run to check that it functions normally. For the procedure for installing optional equipment, see the Installation Procedures supplied with it.
205
MEMO
206
Chapter 6
Maintenance/Check
z Guaranteed Periodical Maintenance .......................208 x Cleaning and Oiling ..................................................208 (1) Cleaning ...............................................................208 (2) Oiling ....................................................................208 c Periodical Maintenance ............................................209 (1) 6-month Periodical Checking ..............................209 (2) Criteria for Replacing the Primary Parts ...........209
207
chap.6
z Guaranteed Periodical Maintenance x Cleaning and Oiling
zGuaranteed Periodical Maintenance

The serviceman will visit the user periodically after delivery. The maintenance operation described in the periodical maintenance list is performed and instructs how to follow the operation. When the serviceman is called by telephone, the following maintenance must be performed after clearing the trouble.
1. Cleaning the document. 2. Cleaning the document table glass. 3. Cleaning the thermal head.
xCleaning and Oiling

(1) Cleaning
1.Paper shreds: Clean with a brush or dry cloth. Clean the mirror and reflection plate in the scanner section with a blower brush. 2.Ink: Clean with soap. Oil or grease after ink or paper shreds are removed.
(2) Oiling
1.Bearing section: Oil the edge surface and bearing sections with oiler, rotating the lever and roller.
IMPORTANT : Do not oil the pinch lever bearing section. Clean it.
2.Gear section:
Grease the gear section after removing paper shreds on the bottom of gear.
208
chap.6
c Periodical Maintenance
cPeriodical Maintenance
(1) 6-month Periodical Checking
Section to be checked Shading plate Glass Lamp Reflection mirror Thermal head Platen roller Sensor Press roller Drum exterior Paper feeding section Plate making section Roller shaft / bearing Gear Air pump Escape cam Description Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Checking Checking Oiling Greasing Greasing Greasing Remarks Clean with a soft and clean cloth Clean with a soft and clean cloth Clean with a soft and clean cloth Remove dust with blower brush Clean with a soft and clean cloth (Do not damage the thermal head) Remove paper shreds (Do not damage the platen roller) Remove dust with blower brush Remove paper shreds Remove ink and paper shreds Paper is fed smoothly. Remove paper shreds Paper is fed smoothly. Remove paper shreds Except for the pinch lever bearing section
(2) Criteria for Replacing Primary Parts

No. 1 2 3 4 5 6 7 8 Paper feed roller Paper separator unit Thermal head Drum unit Air pump Tape cutter upper/lower blade Press roller Lamp Item Criterion 300,000 sheets or more 300,000 sheets or more About 20,000 plates or one year Printing 1,000,000 sheets or one year Printing 1,000,000 sheets or one year Cutting 10,000 times or one year 1,000,000 sheets or one year 10,000 plates or one year Up to 10 voids Overhaul Remarks
209
MEMO
210
Chapter 7
Troubleshooting
z Troubleshooting Guide ............................................212 1.Countermeasures for the Defective Operation ...212 (1) "LAMP NG" is displayed ....................................213 (2) Lamp does not Light Up ....................................213 (3) "E001" is displayed ............................................214 (4) "E002" is displayed ............................................215 (5) "E008" is displayed ............................................216 (6) "E009" is displayed ............................................216 (7) "E0014"(LPU) is displayed ................................216 (8) "DRUM NOT SET" is displayed ........................217 (9) "MASTER SET MISS" is displayed ...................217 (10) Malfunction of Master Feeding Clutch ...........218 (11) Malfunction of Platemaking Stepping Motor .218 (12) "MAST. EJECT ERROR" is displayed ............219 (13) Malfunction of Roll-up Motor ..........................219 (14) "SET PRINT PAPER" is displayed ..................220 (15) "FRONT COVER OPEN" is displayed ............220 (16) "DOC. TRAY OPEN" is displayed ...................221 (17) "ROLL MASTER END" is displayed ...............221 (18) "EXCHANGE INK" is displayed .....................222 (19) "SET KEYCARD" is displayed ........................222 (20) "DOCUMENT JAM" is displayed, when power turned on .........223 (21) "PAPER RIGHT JAM" is displayed ................224 (22) "PAPER LEFT JAM" is displayed ...................225 (23) "EXCHG. EJECT-CORE" is displayed ............225 (24) Paper Jams in the Paper Feed Side ................226 (25) Paper Jams in the Paper Eject Side ................227 x Error Display .............................................................228
211
chap.7
zTroubleshooting Guide
1. Countermeasures for the Defective Operation
When the messages listed below are displayed on the LCD or when trouble such as malfunctioning or a paper jam occurs, proceed with an inspection following the procedure for the item and take measures accordingly.
Message List
Massage Remarks No. (16) When power turned on (20) (8) (23) (18) (15) (1) (12) (9) (22) (21) (17) Specification for export Specification for domestic (19) (19) (14) (3) (4) (5) (6) Machine with LPU connected (7) Page 221 223 217 225 222 220 213 219 217 225 224 221 222 (English) 222 (Japanese) 220 214 215 216 216 216
DOC. TRAY OPEN DOCUMENT JAM DRUM NOT SET EXCHG. EJECT-CORE EXCHANGE INK FRONT COVER OPEN LAMP NG MAST. EJECT ERROR MASTER SET MISS PAPER LEFT JAM PAPER RIGHT JAM ROLL MASTER END SET KEYCARD SET KEYCARD SET PRINT PAPER E001 E002 E008 E009 E014
Error item List

Item No. (2) (10) (11) (13) (25) (24) Page 213 218 218 219 227 226
Lamp does not light up Malfunction of master feeding clutch Malfunction of platemaking stepping motor Malfunction of roll-up motor Paper JAM in the paper eject side Paper JAM in the paper feed side
212
chap.7
(1) "LAMP NG" is displayed

Cause/Defective section Procedures Lamp does not light up ADF cover (Scanner cover) Mirror Main PCB unit Item to be checked Does lamp light up when power is turned on for an instant? Is trouble cleared by closing ADF cover and then turning OFF and ON or pressing ALL CLEAR key? Is mirror dropped off or broken? HELP mode(H-08)*: Is CCD photoreceiving data not less than 26? Result NO YES Countermeasure Refer to Lamp does not light up. Finish.
1 2 3 4
YES YES
Install mirror in place. Replace main PCB unit.
(2) Lamp does not Light Up

Cause/Defective section Procedures Item to be checked Does voltage between drive PCB unit CN7-3(+) and CN7-2(GND) show +24V? Does lamp light up when drive PCB unit CN5-1 is short-circuited to GND? Result NO Countermeasure Proceed to procedure 5.
1 2
Lamp Inverter PCB Unit
YES
Proceed to procedure 4.
Is trouble cleared by replacing lamp?
YES NO
Finish. Check bundled wire and connectors and replace inverter PCB unit. Finish. Check bundled wire and connectors and replace main PCB unit. Check bundled wire and connectors on primary side and if necessary replace drive PCB unit. Check bundled wire and connectors and replace thermal head. Check bundled wire and connectors on primary side and if necessary replace regulated power supply. Check bundled wire, connectors and DC motor and replace drive PCB unit.
Drive PCB unit Main PCB unit
Is trouble cleared by replacing drive PCB unit?
YES NO
Drive PCB unit
Does voltage between regulated power supply CN2-1(+) and CN31(GND) show +24V? Is measured voltage by procedure 1 +24V after drive PCB unit CN6 is pulled out? Is measured voltage by procedure 5 +24V after drive PCB unit CN7 is pulled out?
YES
Thermal head
6 7
YES
Regulated power supply
NO
Drive PCB unit
YES
213
chap.7
(3) "E001" is displayed

Cause/Defective section Procedures Item to be checked Does drum rotate? Is trouble cleared by replacing main motor PCB unit? Does motor rotate without drum? Does main motor rotate without the driving timing belt? Does main motor rotate at pre-stop speed if main motor PCB unit CN3-8 is short-circuited to GND? Is the trouble cleared by replacing main motor PCB unit? Result NO YES NO YES YES Countermeasure Proceed to procedure 5. Finish. Replace main PCB unit. Eliminate interference. Check if drive system gear is broken or blocked with foreign matter and remove cause. Check bundled wire and connectors, and if necessary replace main PCB unit. Finish. Replace main motor.
Main motor PCB unit Main PCB unit Drum interferes with body. Drive system gear broken or blocked with foreign matter. Main PCB unit
1 2 3 4 5 6
YES
Main motor PCB unit Main motor
YES NO
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chap.7

Cause/Detective section Procedures Feed tray operation is defective Items to be checked Does the elevator motor work when the chain is removed from the feed tray? Check with the HELP modes, H-06, H07. Are the elevator top limit sensor and the elevator bottom limit switch noraml? Remove the drive PCB Unit CN2. Measure the voltage between the regulated power supply, CN1-1(+), CN1-2 (GND) with the tester. Is the voltage +24 V? Measure the voltage between the main PCB Unit CN3-1 (GND) and CN3-2 (+) with the tester at the timing of the elevator motor operation. Is the voltage +24V whether the elevator motor relay connector is inserted or not? Is the cause cleared by replacing the drive PCB Unit? Measure the voltage between the main PCB Unit CN6-2 (+) and GND with the tester. Is the voltage of the elevator top limit sensor 0V at the time of photopassing and 5V at the time of photointerrupting? Measure the voltage between the main PCB Unit CN6-1 (+) and CN6-3 (GND) with the tester. Is the voltage +5V? Check the elevator bottom limit switch with the tester. Is the switch turned on or off normally? Result YES Countermeasure Remove the cause of defective operation. Lean or catch? Follow the procedure 6 when the elevator top limit sensor is defective. Follow the procedure 8 when the elevator bottom limit sensor is defective.
NO
NO
Replace the regulated power supply.
Elevator motor
YES
Replace the elevator.
Drive PCB Unit
YES NO
Finish. Replace the elevator motor.
5
Elevator motor
Main PCB Unit
YES
Replace the main PCB Unit.
Main PCB Unit
YES YES NO YES
Replace the main PCB Unit. Replace the elevator top limit sensor. Replace the elevator bottom limit SW. Replace the main PCB Unit.
7
Elevator top limit sensor Elevator bottom limit SW
8
Main PCB Unit
* *
HELP mode H-06 \ see p.245 HELP mode H-07 \ see p.246
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chap.7

Cause/Detective section Procedures Online set PCB Unit Online code IPC I/F PCB Unit Main PCB Unit Items to be checked Is the cause cleared by replacing the online set PCB Unit ? Is the cause cleared by replacing the online code ? Is the cause cleared by replacing the IPC I/F PCB Unit ? Result YES YES YES NO Finish. Finish. Finish. Replace the Main PCB Unit. Countermeasure
1 2 3

Cause/Detective section Procedures Items to be checked Use a tester to measure the voltage between DC regulated power supply CN2-1(+) and the frame (GND). Is the voltage 16 - 18V during platemaking (thermal head ON)? Disconnect all the thermal head connectors, and measure the voltage in 1) above. Is the voltage 16V approx.? Disconnect DC regulated power supply CN2 and drive PCB CN7, and measure the voltage in 1) above. Is the voltage 16V approx.? Result Countermeasure
Main PCB Unit
YES
Chech the bundled wire and connector. If OK, replace the main PCB Unit.
Thermal head
YES
Chech the bundled wire and connector. If OK, replace the thermal head. Chech the bundled wire and connector. If OK, replace the drive PCB Unit. Replace the regulated power supply.
Drive PCB Unit Regulated power supply
YES NO

Cause/Detective section Procedures Items to be checked
(only in machine with Long Paper Unit connected) Result Countermeasure
Execute printing in the regular mode. Does the guide roller drive motor turn?
YES
Follow the procedure 5.
Thermal head press motor
Execute printing in the regular mode, and measure the voltage between the drive PCB unit's CN4-9 (+) and CN4-10 (GND). Is the voltage +24V? Measure the voltage between the DC regulated power supply's CN2-1 (+) and CN3-1 (GND).Is the voltage +24V?
YES
Check the bundled wire. If OK, replace the guide roller drive motor.
Regulated power supply Drive PCB unit
NO YES
Replace the regulated power supply. Finish. Check the bundled wire and connectors between the drive PCB unit's CN10 and the mini drive PCB unit's CN1. If OK, replace the main PCB unit. Finish.
4
Mini drive PCB unit
Replace the drive PCB unit. Is the problem solved?
NO
Guide roller sensor
Replace the guide roller sensor. Is the problem solved?
YES
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chap.7
(8) "DRUM NOT SET" is displayed

Cause/Defective section Procedures Drum setting. Main PCB unit Item to be checked Is trouble cleared by setting drum again? Does drum SW (MS4) checked by HELP mode (H-08)* prove to be normal? Does drum SW (MS4) checked by volt-ohm-milliammeter prove to be normal? Result YES YES Finish. Check if drum SW (MS4) is installed in place and replace main PCB unit. Replace drum SW (MS4). Check if drum SW (MS4) is installed in place and replace main PCB unit. Countermeasure
1 2 3
Drum SW Main PCB unit
NO YES
*
(9) "MASTER SET MISS" is displayed
Cause/Defective section Procedures End mark sensor PCB unit (PS3) Item to be checked Has MASTER SET MISS actually occurred? Result NO
Countermeasure Adjust VR for end mark sensor by HELP mode (H-13)*. If unable,replace end mark sensor PCB unit. IMPORTANT: VR must be adjusted after replacement of end mark sensor PCB unit. Refer to (10) Malfunction of master feeding clutch (CL1).
Master feeding clutch (CL1)
Does master feeding clutch (CL1) operate normally?
NO
\ see page 218

Platemaking stepping motor (PM2)
Does platemaking stepping motor (PM2) operate normally?
NO
Refer to (11) Malfunction of platemaking stepping motor (PM2). Replace cutter unit.
\ see page 218
Cutter unit Static electricity Master Transfer path
4 5 6
Is master cut normally? Is static-eliminating brush on master feeding unit damaged or deteriorated? Is trouble cleared by replacing master?
NO YES YES NO
Remove static-eliminating brush. Finish. Remove any foreign matter in transfer path.
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(10) Malfunction of Master Feeding Clutch

Cause/Defective section Procedures Regulated power supply Item to be checked Does voltage between regulated power supply CN2-1 (+) and CN3-1 (GND) show 24V? Does voltage between drive PCB unit CN4-7 (+) and -8 (GND) show 24V when master feeding clutch is turned on? Is trouble cleared by replacing drive PCB unit? Result NO Countermeasure Replace regulated power supply.
1 2
Master feeding clutch (CL1)
YES
Check wiring and replace master feeding clutch.
YES NO
Finish. Check bundled wire and connectors and replace main PCB unit.
(11) Malfunction of Platemaking Stepping Motor

Cause/Defective section Procedures Load on drive system Item to be checked Is trouble cleared by adjusting tension of the master feeding unit timing belt or supplying oil to bearing? Does voltage between regulated power supply CN2-1 (+) and CN3-1 (GND) show 24V? Is trouble cleared by replacing drive PCB unit? Result YES Finish. Countermeasure
1 2 3
NO
Replace regulated power supply.
YES NO
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chap.7
(12) "MAST. EJECT ERROR" is displayed

Cause/Defective section Procedures Item to be checked Has MAST. EJECT ERROR actually occurred? Are there any foreign matter or dirt between the master ejection sensor photo-receiving (PS13) and the master ejection sensor photo-emitting PCB? Is trouble cleared by replacing the master ejection sensor photo-receiving (PS13)? Is trouble cleared by replacing the master ejection sensor photo-emitting PCB? Result YES YES Countermeasure Proceed to procedure 5. Remove any foreign matter and clean.
1
Foreign material or dirt on sensors.
Master ejection sensor photo-receiving (PS13) Master ejection sensor photo-emitting PCB Main PCB unit
3 4
YES
Finish.
YES NO
Finish. Check bundled wire and connectors and replace main PCB unit. Refer to (13) Malfunction of roll-up motor (M4). Clean master clump section. Replace any damaged stripper finger or springs. Adjust the drum master ejection stop position. Check and adjust C mode.
Roll-up motor (M4) Master clump dirty. Master ejection box Drum master ejection stop position C mode
5 6 7 8
Does roll-up motor (M4) rotate normally? Is the master clump section dirty with ink or oil? Is stripper finger or springs damaged? Is the drum master ejection stop position within reference value?
NO YES YES NO YES
(13) Malfunction of Roll-up Motor

Cause/Defective section Procedures Roll-up motor Item to be checked Does voltage between drive PCB unit CN4-14 (+) and -13 (GND) show 24V when roll-up motor (M4) is operated with HELP mode (H-18)*? Does voltage between regulated power supply CN2-1 (+) and CN3-1 (GND) show 24V? Is trouble cleared by replacing drive PCB unit? Result YES Countermeasure Replace roll-up motor (M4).
2 3
NO
Replace regulated power supply.
YES NO
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chap.7
(14) "SET PRINT PAPER" is displayed

Cause/Defective section Procedures Paper sensor (MS7) position Paper sensor (MS7) Main PCB unit Item to be checked Is actuator for paper sensor (MS7) is pressed when paper tray is set? When paper sensor (MS7) is checked with volt-ohm-milliammeter, does it CLOSE if actuator is pressed and OPEN if released? Result NO NO YES Countermeasure Adjust paper sensor (MS7) position. Replace paper sensor (MS7). Check bundled wire and connectors and replace main PCB unit.
1 2
(15) "FRONT COVER OPEN" is displayed

Cause/Defective section Procedures Front cover SW (MS5) position Front cover SW (MS5) Main PCB unit Item to be checked Is front cover SW (MS5) pressed when front cover is set? When front cover SW (MS5) is checked with volt-ohm-milliammeter, does it OPEN if switch is pressed (front cover open) and CLOSE if released (front cover close)? Result NO NO YES Countermeasure Adjust front cover SW (MS5) position. Replace front cover SW (MS5). Check bundled wire and connectors and replace main PCB unit.
1 2
220
chap.7
(16) "DOC. TRAY OPEN" is displayed

Cause/Defective section Procedures Document receiving tray SW (MS3) position. Document receiving tray SW (MS3) Main PCB unit Item to be checked Is the document receiving tray SW (MS3) pressed when document receiving tray is closed? When the document receiving tray SW (MS3) is checked with volt-ohmmilliammeter, does it CLOSE if switch is pressed and OPEN if released? Result NO Countermeasure Adjust the document receiving tray SW (MS3) position. Replace the document receiving tray SW (MS3). Check bundled wire and connectors and replace main PCB unit.
1 2
NO YES
(17) "ROLL MASTER END" is displayed

Cause/Defective section Procedures Adjustment for the end mark sensor PCB unit (PS3). End mark sensor PCB unit (PS3) Main PCB unit Item to be checked Is trouble cleared by adjusting the end mark sensor PCB unit (PS3) by HELP mode (H-13)*? Is trouble cleared by replacing the end mark sensor PCB unit (PS3)? Result YES Finish. Countermeasure
1 2
YES NO
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chap.7
(18) "EXCHANGE INK" is displayed

Cause/Defective section Procedures Ink Setting method of ink pack. Main PCB unit Item to be checked Is enough ink left in ink pack? Is ink pack set properly? Is LED on the ink detection PCB unit lit? Is enough ink left in drum? (Has ink reached detection needle for the ink detection PCB unit?) Does ink pump operate? Is trouble cleared by cleaning inside of ink pump? Result NO NO YES Countermeasure Replace ink pack. Set ink pack properly and teach user how to set one. Check bundled wire and connectors and replace main PCB unit. Replace Ink detection PCB unit.
1 2 3 4 5 6
YES
NO YES NO
Proceed to procedure 7. Finish. Replace ink pump. Replace regulated power supply.
Foreign material in ink pump Ink pump Regulated power supply
7 8 9
Does voltage between regulated power supply CN4-1 (+) and -1 (GND) show 24V? Does voltage between drive PCB unit CN2-1 and -2 show 24V? Is trouble cleared by replacing drive PCB unit?
NO
Ink motor (M2) Drive PCB unit Main PCB unit
YES YES NO
Replace ink motor (M2). Finish. Check bundled wire and connectors and replace main PCB unit.
(19) "SET KEYCARD" is displayed

Cause/Defective section Procedures
specification for export
Item to be checked Is the keycard counter connector connected? Is trouble cleared by inserting department card as keycard? Is the keycard counter connector connected properly? Is HELP mode (H-28)* set to ***0?
Result NO YES NO NO YES
Countermeasure Proceed to procedure 5. Finish. Connect connector properly. Set HELP mode (H-28)* set to ***0. Proceed to procedure 6. Set HELP mode (H-28)* set to ***1. Finish. Replace keycard counter.
1
How to use. Keycard counter connector HELP setting.
2 3 4
HELP setting. Main PCB unit Keycard counter
5 6
Is HELP mode(H-28)* set to ***1? Does voltage between main PCB unit CN6-3 and GND about 5V?
NO YES NO
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chap.7
(20) "DOCUMENT JAM" is displayed, when power turned on

Cause/Defective section Procedures Item to be checked Does the document feed roller rotate? Is document fed by separator and the paper feed roller? When document sensor 1 (PS1) is checked with HELP mode (H-08)*, is 0 displayed if sensor is photo passing and is 1 displayed if photointerrupted? Does voltage between main PCB unit CN13-2 and GND show HIGH value (about 4.5V) if sensor is photointerrupted and LOW if photo passing? Does the sensor indicate "1" when there is paper and "0" when there is no paper? Does the sensor indicate "10 or lower" when there is paper and "255" when there is no paper if it is checked by HELP mode (H-08)*? Are gears broken? Does voltage between regulated power supply CN4-4 (+) and -1 (GND) show 24V? Is trouble cleared by replacing drive PCB unit? Is trouble cleared by replacing main PCB unit? Result NO NO YES Countermeasure Proceed to procedure 7. Clean separator and the paper feed roller. If necessary, replace. Check bundled wire and connectors and replace main PCB unit. Replace main PCB unit.
Separator, paper feed roller Main PCB unit
1 2 3
Main PCB unit
YES
Scanner JAM sensor
5 6
NO
Replace the scanner JAM sensor.
NO
Replace the document position sensor.
Gears Regulated power supply
7 8 9 10
YES NO
Replace gears. Replace regulated power supply.
Drive PCB unit Main PCB unit Scanner stepping motor (PM1)
YES YES NO
Finish. Finish. Replace scanner stepping motor (PM1).
223
chap.7
(21) "PAPER RIGHT JAM" is displayed

Cause/Defective section Procedures Paper Item to be checked Is printing paper long within specified value? When JAM sensor 1 (PS12) is checked with HELP mode (H-08)*, is 0 displayed if sensor is photopassing and is 1 displayed if photointerrupted? Is paper really jammed at master ejection section? Is trouble cleared by properly closing the master ejection box? Is there any dirt or foreign material on the JAM sensor photo-emitting or photo-receiving section? Is trouble cleared by adjusting the JAM detection sensor position? Is 0 displayed by directing another light to the photo-receiving section of the document sensor photo-receiving PCB when JAM sensor 1 (PS12) is checked with HELP mode (H-06)*? When drum is checked with HELP mode (H-06)* while rotating slowly, does the stop/JAM detection position sensor (PS6) display 0 or 1 according to edge of photointerrupter? Result NO YES Countermeasure Use paper conforming to specification. Proceed to procedure 7.
1 2
Paper jammed
3 4 5 6 7
YES
Refer to (25) Paper JAM in paper eject side.
\ see page 227

Master ejection box is not closed. Dirt or foreign material on sensor Sensor position JAM sensor photo-emitting PCB JAM sensor photo-receiving PCB Stop/JAM detection position sensor (PS6) Main PCB unit YES YES Finish. Clean the photo-emitting and photo-receiving sections of JAM sensor. Finish. Replace JAM sensor photoemitting PCB. Replace JAM sensor photoreceiving PCB. Adjust position of the stop/JAM detection position sensor. If necessary, replace. Replace main PCB unit.
YES YES NO
NO
YES
* *
HELP mode H-06 \ see p.245 HELP mode H-08 \ see p.247
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chap.7
(22) "PAPER LEFT JAM" is displayed

Cause/Defective section Procedures Item to be checked Is trouble cleared by checking, referring to (24) Paper jams in the paper feed side? Result YES Finish. Countermeasure
\ see page 226
Main PCB unit
When P roller sensor (PS9) is checked with HELP mode (H-06)*, is 0 displayed if press is turned ON and 1 displayed if OFF? NOTE: If no problem is detected by the check with HELP mode (H-06)*, result on printing may differ depending on speed or load. Recommended is to follow procedure 3 and 4 below for further check. Is the trouble cleared by adjusting P roller sensor (PS9) position? Is the trouble cleared by replacing P roller sensor (PS9)?
YES
Replace the main PCB unit.
P roller sensor (PS9) position P roller sensor (PS9) Main PCB unit
3 4
YES YES NO
Finish. Finish. Check the bundled wire and connectors and replace the main PCB unit.
(23) "EXCHG. EJECT-CORE" is displayed

Cause/Defective section Procedures Core Core full SW (MS8) actuator Core full SW (MS8) Main PCB unit Item to be checked Core is not included or core is full? Is core full SW (MS8) pressed when empty core is installed? Does core full SW (MS8) tested voltohm-milliammeter prove to be normal? Result YES YES NO YES Countermeasure Insert new core. Adjust actuator of core full SW (MS8). Replace core full SW (MS8). Check bundled wire and connectors and replace main PCB unit.
1 2 3
225
chap.7
(24) Paper Jams in the Paper Feed Side

Causes Printing paper not suitable Symptoms If paper is too thick, it wont be likely fed. If too thin, double sheets may be fed. Paper not clearly cut: 2 sheets still adhere to each other. Much paper scraps may deteriorate the paper feed roller and separator performance. Paper gets stuck in transfer path, causing creasing and tearing. If pressure on paper is insufficient, paper will not be fed. If pressure on paper is excessive, double sheets will be fed. Paper may not be fed. If gap is too large, separator unit will rattle in direction of paper transfer path, causing double sheets to be fed. If gap is too small, paper separator unit cannot follow angle change due to paper feed shaft up-down movement, which may cause double-sheet or slanted feed, and creasing. Wear, or adhesion of paper scraps causes deterioration in separating performance, resulting in double-sheet feed. Countermeasure Explain causes to user. Have user change to the paper conforming to specifications.
Dirt / foreign matter in transfer path Incorrect paper feed path pressure Worn paper feed roller Paper separator unit gap
Remove any dirt or foreign matter. Explain to users how to select correct pressure for paper. Replace paper feed roller. Perform paper separator unit gap adjustment.
\ see page 171

Clean separating surfaces. If any trouble exists, replace. Perform separator unit gap adjustment on new unit. \ see page 171 Perform separation pressure adjustment.
Paper separator unit
Separation pressure
If pressure is very low, no paper will be fed.
\ see page 172
Paper tray upper position limit
Paper slant is large, causing creases. During printing, paper feed errors often occur immediately before or after paper tray rises. If amount is too short, paper slant cannot be corrected, printing position may not be uniform, or paper may not be fed. If amount is too long, loop becomes too large, causing paper to buckle up between paper feed roller and timing roller, resulting in feed error. Clutch slippage will reduce paper feed amount. If clutch does not disengage properly, the paper feed segment gear will not return correctly, leading to reduced feed amount. (See Paper feed amount above.) If Guide roller pressure is insufficient, paper will not be gripped properly, and timing roller will not assure constant feed amount. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. If there is a gap between Guide roller and the timing roller, paper slant cannot be corrected. If the timing roller clutch slips, feed amount will not be constant. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. If the timing roller clutch does not disengage properly, the paper feed segment gear will not return correctly, leading to reduced and unstable feed amount. As a result, printing position will not be uniform. In the worst case, no paper will reach drum. Paper may be damaged in the part of leading edge that touches the signal lever. In the worst case, paper may stick to the signal lever.
Perform paper feed tray upper limit sensor adjustment.
\ see page 172

Perform paper feed amount adjustment.
Paper feed amount
HELP mode H-67 / 291 page

Replace paper feed cluch.
Paper feed clutch
Guide roller pressure & timing
Perform escape amount adjustment and escape timing adjustment.
\ see page 174

Clean timing roller clutch . Replace if necessary.
Timing roller
Incorrect signal lever operation
Clean bearing unit. Check that signal lever moves smoothly.
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chap.7
(25) Paper Jams in Paper Eject Side

Causes Printing paper not suitable Symptoms If paper is too thin, it will stick to drum and scrunch up. If grain of paper is sideways relative to transfer direction, paper will crunch up, or get jammed on the paper receiving plate. If paper curl upward, it will likely scrunch up. If curl downward, it will likely get jammed on the paper receiving plate. If set-solid exists near leading edge of paper, paper will likely scrunch up. If set-solid is blasted to one side of paper, paper will not be ejected in a straight line. As a result, ejected paper will be disorderly piled and likely jam on the paper receiving plate. If ambient air is dry, static electricity may cause disordered piles or scrunch-up of paper. Countermeasure Explain causes to users. Have user change to paper conforming to specifications.
Image of document
Adjust leading edge margin to about 10 mm. (Too long margin will cause adverse results.) Explain causes to users. If possible, have user change position for set-solid. Explain causes to users. Have user desist from excessive use of A/C or heating. If possible, have user take anti-dryness measures including humidifiers. Perform printing position sensors adjustment.
Static electricity
Leading edge margin
If leading edge margin is not correct, scrunch-up of paper will likely result. IMPORTANT: Scrunch-up of paper may also result if the margin is too long. If Guide roller pressure is insufficient, paper will not be gripped properly, causing less feed amount determined by timing roller, or disappearance of leading edge margin. This results in the paper scrunchup. Any slippage of the timing roller clutch will reduce feed amount and eliminate leading edge margin. This results in the paper scrunch-up. If the timing roller clutch does not disengage properly, the timing roller segment gear will not return correctly, causing reduction of feed amount or disappearance of leading edge margin. As a result, paper will scrunch up. If timing is too low, or the gap between drum and the leading edge of paper is too large, paper stripper finger will not enter into the gap, causing the paper scrunch-up. If sufficient air is not delivered from the tip of the paper stripper finger, it will not lift the leading edge of paper off drum. Scrunch-up of paper will result.
\ see page 175

Perform escape amount and escape timing adjustments.
Guide roller pressure & timing
\ see page 174

Clean timing roller clutch. Repair if necessary.
Timing roller clutch
Perform paper stripper finger adjustment.
\ see page 180
Air
Check if the hole in the fingers tip is blocked by foreign matter. Check pipes for kinks or disconnections. Check valves and O-rings on the air pump. If the belt is broken or stretched, replace it.
Paper ejection belt
If the speed of the paper ejection belt, if cannot eject the paper onto the paper receiving plate with sufficient force. As a result, there will be paper jams in the vicinity of the discharge port. (Sometimes the trailing edge of the paper gets caught in the jamming sensor and a paper jamming error is displayed.) If the suction force of the fan drops, it will not be able to blow the paper (which has risen clear of the ejection belt) onto the paper receiving plate with be paper jams in the vicinity of the discharge port. (Sometimes the trailing edge of the paper gets caught in the jamming sensor and a paper jamming error is displayed.) Too much ink transferred to paper will likely cause scrunch-up of paper.
Paper ejection fan unit
Clean the fan. If it still does not work properly, replace it.
Ink
Perform ink volume adjustment of drum. Explain user that ink transfer volume increases immediately after paper scrunchup, and advise user to restart printing at standard speed, then.
\ see page 182
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chap.7
xError Display
This machine has a self-diagnosis function. The state of the machine is always checked with this function and is displayed with code on the control panel. The following are the code display, cause and detection timing.
LCD panel
E111
Code display
Code display
Cause The main motor (M1) is defective. The main motor PCB Unit is defective. The main PCB Unit is defective. The encoder sensor (PS7) is defective. The elevator motor (M2) is defective. The elevator top limit sensor (PS9) is defective. The elevator bottom limit switch (MS6) is defective. The drive PCB is defective. - The main PCB Unit is defective. The elevator operation is defective. The lamp is defective. The invertor unit is defective. The CCD is defective. Main PCB unit is defective. The I/F PCB unit is defective. IPC I/F PCB unit is defective. The regulated power supply is defective. The thermal head PCB is defective. The thermal head is defective. The regulated power supply is defective. The mini drive PCB is defective. The guide roller driving motor is defective. The guide roller sensor(LPU escape timing) is defective. The main PCB unit is defective.
Detection timing
E001
While the drum rotation signal is lit, the encoder sensor (PS7) cannot detect the edge for 1 second.
E002
The elevator does not reach the top limit for 30 seconds after the elevator motor (M2) up signal is lit. The elevator does not reach the bottom limit for 30 seconds after the elevator motor (M2) down signal is lit.
E004
In the lamp lighting check, amount of light received by CCD does not reach regulation value. (Perform the lamp lighting check once only, with the power turned on.) During on-line platemaking, communication error occurs between main PCB unit and I/F PCB unit. At start of platemaking, thermal head drive voltage does not reach regulation value.
E008 E009
E014
While the LPU driving signal is lit, the LPU escape sensor cannot detect the edge for 2 seconds.
228
Chapter 8
HELP Mode
Pz HELP Mode List .........................................................230 x Overview ....................................................................234 c HELP Mode Functions and Operation Procedures .............................235 (1) Basic Procedure for Accessing HELP Modes ......235 (2) Guide to the HELP Mode Descriptions................235 HELP Mode Descriptions.....................................236
229
chap.8
z Help mode List
z HELP Mode List

HELP Mode No. H-00 (1) Display of ROM versions (2) ROM version upgrading (1) Display and adjustment of print speeds (2) Initialization of print speeds (3) Function testing of paper feed clutch (1) Function testing of elevator motor (1) Function testing of TAPE CLUSTER (1) Function testing of ink replenishment (1) Checking of condition of master ejection sensor and other sensors listed below Master ejection sensor Paper feed sensor Top/Bottom limit sensor, Top/Bottom center sensor (1) Checking of condition of sensors listed below: Drum master attachment /detachment position sensor , Paper ejection jam sensor , Drum stop/paper ejection jam Paper sensing position sensor , Press roll sensor Encoder sensor , Elevator top limit sensor, A/C mode sensor, B mode sensor Description Classification ROM version displays / upgrading Adjustment t / specification setting Function testing Function testing Function testing Function testing Page (1) 236 (2) 237 (1) 238 (2) 239 (3) 240 241 242 243
H-01
H-02 H-03 H-04
H-05
Sensor/ switch condition display
244
H-06
Sensor/ switch condition display
245
H-07
(1) Checking of condition of switches listed below: ADF cover switch, Feed tray descend switch, Jog switch (drum Sensor/ switch condition rotation switch), Master cover switch, Master lever switch, Elevator display lower limit switch, Paper sensor, Drum cover switch (1) Checking of condition of sensors/swtches listed below: Sensor/ switch condition Document sensor, Scanner JAM sensor, Document position sensor display Drum switch, Master roll Full switch, Top cover open/closed detection switch (1) Checking of master attachment position, jam sensing position, master detachment position and drum stop position (1) Function testing of lamp (2) Function testing of ADF clutches (1) Display of document darkness values / scanner test (for use in factory checks) (1) Checking of shading memory, thermal head and main PCB unit synchronized signals (1) Check the condition of the end mark sensor and master position sensor (2) Function testing of master feeding clutch Function testing Function testing Sensor/ switch condition display Function testing Sensor/ switch condition display Function testing
246
H-08
247
H-09 H-10 H-11 H-12
248 (1)249 (2)249 250 251 (1)252 (2)253
H-13
230
chap.8
z Help mode List
HELP Mode No. H-14 H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26 H-27
Description (1) Platemaking total counter display (2) Resetting of count of total plates made in user mode (1) Function testing of ink motor (1) Correction of platemaking start position during online platemaking (1) Function testing of cutter motor (1) Function testing of roll-up motor (1) Printing total counter display (2) Resetting of count of total sheets printed in user mode (1) Function testing of clump motor and clump position sensing (A /B /C mode position) (Not used) (1) Setting of lengthwise zoom factor correction amount for platemaking side (1) Setting of photograph mode document sensing darkness (1) Setting of reducing offset for reading longitudinal R / E of scanner (1) Setting of enlarging offset for reading longitudinal R / E of scanner (1) Compensation of document darkness white level in photograph mode (1) Initialization of all HELP mode settings (1) Setting : TAPE CLUSTER presence/absence Buzzer selection KEYCARD COUNTER 2 specification (1) Adjustment of paper infeed amount
Classification Total counts Function testing Adjustment / specification setting Function testing Function testing Total counts Function testing 4 Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting
Page (1) 254 (2) 254 255 256 257 258 (1) 259 (2) 259 260 4 261 262 263 264 265 266
H-28
267
H-29 H-30 H-31
268 269 270
(1) Test pattern (all shading sub-scanning direction zoom factor adjustment) Function testing platemaking and printing (1) Setting of number of pre-print sheets (1) Setting : Confidential safeguard function First print speed Master ejection error sensing (1) Compensation of document darkness white level in text mode Adjustment /specification setting Adjustment /specification setting Adjustment /specification setting
H-32
271
H-33
272
231
chap.8
z Help mode List
HELP Mode No. H-34 H-35 H-36 H-37 H-38 H-39 H-40 H-41 H-42 H-43 H-44 H-45 H-46 H-47 H-48 H-49 H-50 H-51 H-52 H-53 (Not used)
Description
Classification 4 Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting 4 4 Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting 4 4 4 4 4 Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting Adjustment/specification setting
Page 4 273 274 275 4 4 276 277 278 279 280 4 4 4 4 4 281 282 283 285
(1) Adjustment of scanner leading edge sensing position (1) Adjustment of scanner widthwise (operation side) sensing position (1) Adjustment of platemaking start position when scanner is used (Not used) (Not used) (1) Correction of outline highlight when scanner is used Setting of platemaking area (sub-scanning direction) (1) Automatic initialization of the control panel setting Setting of repeat count display (1) Setting of paper selection specification Setting of platemaking area (main-scanning direction) (1) Offset value for the thermal head drive energy (1) Setting of thermal head resistance ranking (Not used) (Not used) (Not used) (Not used) (Not used) (1) Setting of text mode document sensing darkness (1) Setting of darkness for test pattern platemaking (1) Setting of online conditions (1) Adjustment of widthwise (operation side) platemaking start position for online platemaking
232
chap.8
z Help mode List
HELP Mode No. H-54 (Not used)
Description
Classification 4 Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting 4 4 4 Adjustment /specification setting 4 4 Adjustment/specification Setting 4
Page 4
H-55
(1) Setting : Ink check at printing start Cutting operation mode for master cutting Interlocks (1) Setting for selecting manipulation language (1) Setting of online conditions (Not used) (Not used) (Not used) (1) Selection of LCD specification (Not used) (Not used) (1) Buzzer (tone) setting (Not used)
286
H-56 H-57 H-58 H-59 H-60 H-61 H-62 H-63 H-64 H-65
287 283 4 4 4 288 4 4 289
H-66
(1) Setting : Clump opening/closing timing of when a master is attached Adjustment/specification Loop sensor ON/OFF Setting Paper size mode (long size) (1) Setting of paper feed length (1) Setting of paper feed timing (1) Setting of model (1) Option setting 1 (Not used) (Not used) (Not used) (Not used) (Not used) (1) Document darkness correction for text/photograph mode Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting Adjustment/specification Setting 4 4 4 4 4 Adjustment/specification Setting
290
H-67 H-68 H-69 H-70 H-71 H-72 H-73 H-74 H-75 H-76
291 292 293 294 4 4 4 4 4 295
233
chap.8
x Overview
x Overview
The DUPRINTER's HELP modes can be broadly classified into the following types:
x Modes for ROM version display / version upgrade

These modes display the version numbers of the main PCB unit's ROM (U12), the I/F PCB unit's ROM (U10) and permit version upgrade of the main PCB unit's U12 ROM.
x Modes for adjustment / specification setting

These modes set the functioning of variable resistors and switches by using the battery PCB unit's EEPROM to memorize settings made on the operation panel. All of these adjustments and settings are made at the factory prior to shipment of each DUPRINTER.
IMPORTANT : New adjustments and appropriate settings must be made after the
battery PCB unit is replaced and after initialization setting has been implemented (using HELP mode H-27).
x Modes for function checks

These modes permit the running of function checks on: individual motors, given series of operations, and electrical circuits. When these modes are used to check motor functioning, the motor being checked is run by itself, but interlocks are suspended. When such checks are run, take care not to put hands or fingers in motor-related moving parts that could start up unexpectedly.
Failure to heed the above could result in crushed or otherwise injured hands or fingers.
x Modes for sensor and switch displays

These modes provide displays of the conditions of sensors and switches.
x Modes for total count displays

These modes provide displays of the counts of the total number of plates made and sheets printed by the DUPRINTER since it was manufactured. They also permit resetting of the total count values displayed in the user mode.
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chap.8
c HELP Mode Function and Operation Procedures
c HELP Mode Functions and Operation Procedures

(1) Basic Procedure for Accessing HELP Modes q During use of the DUPRINTER: first put the machine into the
standby state, then turn the Power switch OFF.
wSimultaneously press and hold down the
and
PRINTING
HELP
SELECT
00
SPEED ADJUSTMENT keys, and turn the Power switch ON with those keys held down. After about 2 seconds, a beep-beep-beep tone will sound, and the HELP mode display will appear.
eUsing the numeric keys, enter the number of the HELP mode you
want to access. Example: To access HELP mode H-00, enter [0], [0].
NOTE : Alternatively, the and PRINTING SPEED ADJUSTMENT
keys may be used to select the HELP mode number.
rPress the PRINT
key. The HELP mode specified in
e will be
V1 . 11
OP 1
V1 . 11
accessed, and either the initial value (value set at factory), or the currently set value, for the mode will be displayed. From this point on, follow the procedure given below for the particular mode accessed.
Mode number flashes
(2) Guide to the HELP Mode Descriptions

The descriptions of each HELP mode given on the following pages are laid out as follows: HELP mode number Function category
chap.7
HELP mode
1. Functions
H-03
(1)Function testing
(1) Tape cluster function test
For desccription of operation \See page 150
Main functions
(2) Stacker rise/descent motor function testing
For removal \See page 195
References to related pages
Operation procedure for individual functions
2. Operation procedure (1) Testing the tape cluster's functioning qAccess HELP mode H-03, and press the PRINT
key. For the basic procedure for accessing HELP modes. \See page 293
H - 0 3
Mode number flashes
LC display for function
wPress and hold down the TEST PRINT
key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down.
235
chap.8
HELP Mode Descriptions

HELP mode
1. Functions (1) Display of ROM versions
Displays version of the main PCB unit's ROM (U12). Displays version of the I/F PCB unit.
IMPORTANT :
H-00
(1) ROM version displays
ROM version for I/F PCB unit is displayed only when connected with
the computer.
(2) ROM version upgrading

Allows upgrading of the main PCB unit's ROM (U12).
2. Operation procedure (1) Displaying ROM versions qAccess HELP mode H-00, and press the PRINT
For the basic procedure for accessing HELP modes.
key. \See page 235
Displaying ROM version
V1 . 11
0p1
V1 . 11
Displays version of the ROM.

Main PCB unit I/F PCB unit
wPress the STOP
key. The HELP mode selection display will
reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
236
chap.8
HELP mode
H-00
(2) ROM version upgrading

Main PCB unit Insert master ROM
(2) Upgrading of ROM version qDuring use of the DUPRINTER: first put the machine into the
standby state, then turn the Power switch OFF.
wSwitch on only No.1 of SW1 on the main PCB unit.

IMPORTANT : Never turn on No.2 through No.4 of SW1. Turn No. 1 of SW1 from OFF to ON
eInsert a master ROM into the socket of the main PCB unit's U12
ROM.
Mode number flashes
rSimultaneously press and hold down the

those keys held down.
and
PRINTING
SPEED ADJUSTMENT keys, and turn the Power switch ON with
HEL P SE L ECT
00
tPress the [0] numeric key twice (to access HELP mode H-00). yPress the PRINT
key.
V1 . 11
0p1
V1 . 11
ROM version is displayed
uPress the PRINT
key. Copying will begin, and the message "- - - COPYING- - - " will appear in the LCD panel. Copying takes about 40 seconds. When it is complete, the new ROM version will be displayed.
- - - COP Y I NG - - -
V1 . 11
IMPORTANT : DO not turn off the power while "- - - COPYING- - - " is displayed. If you do you will have to repeat the copying operation from the beginning.
0p1
V1 . 11
Upgraded version is displayed
iTurn the Power switch OFF. oRemove the master ROM from the socket of the main PCB unit's
U12 ROM.
Remove master ROM
!0Set switch No. 1 of the SW1 switches to OFF.
Turn No. 1 of SW1 from ON to OFF
237
chap.8
HELP mode
1. Functions
H-01
(1) Adjustment / specification setting
(1) Display and adjustment of print speeds

Display and adjustment of print speeds (pre-stop speed, jog speed and speeds 1-3) * The pre-stop speed is adjusted by means of the main motor PCB unit's variable resistor (VR). Adjusting of Printing Speeds 1-3 \See page 192 Pre-stop Speeds Adjustment \See page 191
(2) Initialization of print speeds
(3) Paper feed clutch function testing
For electrical parts layout \See page 298
2. Operation procedure (1) Adjusting speeds and memorizing the adjusted values qAccess HELP mode H-01, and press the PRINT
key. \See page 235
wSelect the speed you want to adjust.

Speeds 1-3
Press the DOCUMENT MODE SWITCH key as many times as and needed to select the TEXT item. Then use the
111
1st
r pm
2nd 3rd speed
PRINTING SPEED ADJUSTMENT keys to select one of speeds 1 through 3.

STD
Jog speed
Press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT/PHOTOGRAPH item.
Pre-stop speed
Press the DOCUMENT MODE SWITCH needed to select the PHOTOGRAPH item. key as many times as
eSelect the item speed you want to adjust

To select the print speed:
Press the DOCUMENT MODE SWITCH needed to select the PHOTOGRAPH item. key as many times as
238
chap.8
HELP mode
H-01

key and SELECT key to
rUse the FUNCTION SWITCH

adjust the speed value.
Speed Pre-stop JOG 1st. 2nd. 3rd.
Adjustment standard (rpm) Print speed (4 6*) 16 60 78 82 120
* The print speed's pre-stop speed and JOG speed are adjusted by means of the main motor PCB unit's variable resistor (VR), not using the FUNCTION SWITCH and SELECT keys.
tTo display or adjust other another speed(s), repeat steps wthrough r. yPress the STOP
key. The newly adjusted value(s) will be
During memorization:
memorized, and the HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
111 SAVE 111
(2) Initializing speed settings (returning settings to the default settings prior to adjustment at factory)
IMPORTANT : After initialization, the speeds must be readjusted.
\See page 191
qAccess HELP mode H-01, and press the PRINT

key. \See page 235
HELP
SELECT
01
Mode number flashes
wPress the [ = ]
initialized.
and CLEAR
keys. The settings will be
ePress the STOP
239
chap.8
HELP mode
H-01
(3) Function testing
(3) Testing the paper feed clutch's functioning

IMPORTANT : Call HELP mode (H-02) in advance, set the Paper tray to the upper
most position by keep pressing the FUNCTION SWITCH
key.
\See page (H-02 qwe )
qAccess HELP mode H-01, and press the PRINT

key. \See page 235
The drum rotates.
wPress the TEST PRINT ePress the STOP
key. Proceed with the paper feed operation.

T
240
chap.8
HELP mode
1. Functions
H-02
(1) Elevator motor function testing
2. Operation procedure (1) Testing the elevator motor's functioning qAccess HELP mode H-02, and press the PRINT
key. \See page 235 key. The
wPress and hold down the FUNCTION SWITCH
elevator motor will run, making the paper tray rise, for as long as the key is held down.
eTo stop the elevator motor, either release the FUNCTION SWITCH
key, or de-obstruct the elevator upper limit sensor's light beam.
rPress and hold down the SELECT
key. The elevator motor will
run, making the paper tray descend, for as long as the key is held down.
tTo stop the elevator motor, either release the SELECT
key, or
alter the elevator lower limit switch's condition from closed to open.
yPress the STOP
241
chap.8
HELP mode
1. Functions
H-03
(1)Function testing
(1) Tape cluster function test
For description of operation \See page 119
2. Operation procedure (1) Testing the tape cluster's functioning qAccess HELP mode H-03, and press the PRINT
key. \See page 235
TAPE
TEST
wPress and hold down the TEST PRINT eRelease the TEST PRINT rPress the STOP
T
key. The tape feed motor
will run, and feed out the tape, for as long as the key is held down. key. The tape cutting solenoid will be activated, and the tape will be cut. key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
242
chap.8
HELP mode
1. Functions
H-04
(1) Ink replenishment function testing

Tests functioning of ink replenishment by sensing the ink supplied.
2. Operation procedure (1) Testing the functioning of ink replenishment qAccess HELP mode H-04, and press the PRINT
key. \See page 235
I NK
CHECK
When the PRINT key is pressed, the drum will rotate, and the ink pump run, until the ink sensing PCB unit's LED lamp lights to signal that ink supply is OK. When this lamp lights, a buzzer sounds and the drum and ink pump stop. key. The HELP mode selection display will wPress the STOP reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
243
chap.8
HELP mode
1. Functions
H-05
(1) Sensor / switch condition display
(1) Checking of condition of master ejection sensor and other sensors listed below
Displays amount of light received by master ejection sensor. Runs checks on the paper feed sensor and the top/bottom limit, top/bottom center sensors.
For electrical parts layout \See page 299 Master ejection sensor \See page 77
2. Operation procedure (1) Checking the condition of master ejection sensor and other listed sensors qAccess HELP mode H-05, and press the PRINT key.
\See page 235
wPress and hold down the PRINT
key. For as long as the key is held down, the master ejection sensor's photo-receiving amount will be displayed, as a value between 00 and 63. x Reading the displayed value [00] : Maximum amount of light received [63] : No light received [00 displayed value 45] : No master between sensor components * Displayed value when master present > Displayed value when master absent
11
Amount of light received by master ejection sensor
Top/bottom limit sensor 1 = light beam obstructed Top/bottom center sensor 1 = light beam obstructed Not used Paper feed sensor 1=paper present
eRelease the PRINT
key. A display indicating the conditions of
the following sensors will appear. x Paper feed sensor :A x Top/bottom limit sensor : C x Top/bottom center sensor : D
A:1 B:1 C:1 D:1

rPress the STOP
key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
244
chap.8
HELP mode
1. Functions
H-06
(1) Sensor/switch condition display
(1) Checking of condition of sensors listed below:

Runs checks on the drum master attachment/detachment position sensor, light reception by the paper ejection jam sensor, drum stop / paper ejection jam sensing position sensor, and press roller sensor. Runs checks on encoders, elevator top limit sensor, A/C mode sensor and B mode sensor. Displays amount of light received by paper ejection jam sensor.
2. Operation procedure (1) Checking the condition of the listed sensors qAccess HELP mode H-06, and press the PRINT wRelease the PRINT
x Press roller sensor x Light reception by the paper ejection jam sensor x Drum master attachment/detachment position sensor Drum master attachment / position sensor 1 = light beam obstructed Light reception by the paper ejection jam sensor 1 = light beam obstructed Drum stop / paper ejection jam sensing position sensor 1 = light beam obstructed Press roller sensor 1 = light beam obstructed
key.

:A :C :D
the following sensors will appear.

x Drum stop / paper ejection jam sensing position sensor : B
ePress the PRINT
key once more. For as long as the key is held
A:1 B:1 C:1 D:1

Encoder check 0 or 1 (switches between 0 and 1 each time 8 edges are sensed) Elevator top limit sensor 1 = light beam obstructed A/C mode sensor 1 = light beam obstructed
down, a display indicating the conditions of the following sensors will appear.
x B mode sensor x A/C mode sensor x Encoder checks :A :B :D
x Elevator top limit sensor : C
rPress the DOCUMENT MODE SWITCH
key as many times as needed to select the TEXT/PHOTOGRAPH item. The paper ejection jam sensor's photo-receiving amount will be displayed, as a value between 000 and 255.
B mode sensor 1 = light beam obstructed
x Paper ejection jam sensor [10] and under : Paper present [255] : Paper absent key. The HELP mode selection display will reappear. tPress the STOP a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
A:1 B:1 C:1 D:1
11
Amount of light received by paper ejection jam sensor
245
chap.8
HELP mode
1. Functions
H-07
(1) Checking of condition of switches listed below:

Displays condition of master cover opening/closing switch, drum rotation switch, feed tray descend switch, elevator lower limit switch and ADF cover opening/closing switch as 0 or 1. Displays condition of drum cover switch, paper sensor, elevator lower limit switch, and master lever switch as 0 or 1.
2. Operation procedure (1) Checking the condition of the listed switches qAccess HELP mode H-07, and press the PRINT
key. \See page 235
Master cover opening/closing switch Drum rotation switch Feed ray descend switch ADF cover opening/closing switch 1=open
1=open
1 = PUSH 1 = PUSH
wPress and hold the PRINT
key. For as long as the key is held
down, a display indicating the conditions of the following switches will appear. S ADF cover opening/closing switch : A :B S Feed tray descend switch :C S Drum rotation switch S Master cover opening/closing switch : D
A:1 B:1 C:1 D:1

Drum cover switch 0 = open
eRelease the PRINT

:A :B :C :D
Paper sensor 1=paper present Elevator lower limit switch Master lever switch 1 = PUSH 1=push
the following switches will appear. S Master lever switch S Elevator lower limit switch S Paper sensor S Drum cover switch
A:1 B:1 C:1 D:1

rPress the STOP
246
chap.8
HELP mode
1. Functions
H-08
(1) Checking of condition of sensors and switches listed below:

Displays amount of light received by document position sensor and displays condition of scanner jam sensor, and document sensor as 0 or 1. Displays condition of drum presence switch, master roll FULL switch, and ADF cover open/closed detection switch, as 0 or 1.
For electrical parts layout \See page 298, 299
2. Operation procedure (1) Checking the condition of the listed sensors qAccess HELP mode H-08, and press the PRINT
key. \See page 235
wPress the DOCUMENT MODE SWITCH

needed to select the TEXT item.
key as many times as
ePress and hold down the PRINT
key. For as long as the key is
Amount of light received by document position sensor Scanner jam sensor Document sensor 1=paper absent 1 = jamming
held down, a display indicating the conditions of the following sensors will appear.
:A S Document sensor :B S Scanner jam sensor S Document position sensor : C Document position sensor's photo-receiving amount will be displayed, as a value between 000 and 255. x Paper ejection jam sensor [10] and under : Document present [255] : Document absent
A : 1 B : 1 C : 111
rRelease the PRINT
Drum switch 1 = drum present Not used Paper roll FULL switch Top cover open/closed detection switch 1=ADF cover open 1 = PUSH
the following sensors will appear. S Top cover open/closed detection switch : A :B S Paper roll FULL switch Drum switch : D S
tPress the STOP
A:1 B:1 C:1 D:1
247
chap.8
HELP mode
1. Functions
H-09
(1) Checking of master attachment position, jam sensing position, master detachment position and drum stop position
For Standards / Adjustment \See page 177
2. Operation procedures (1) Checking the master attachment, jam sensing, master position and drum stop positions qAccess HELP mode H-09, and press the PRINT
key. \See page 235
: D R UM P O S . T E S T
Each time the PRINT key is pressed, the drum stop and jam sensing position sensors, and the master attachment/detachment positions sensors, will alternately sense the edge of the shade plate, then stop.
wPress the STOP
248
chap.8
HELP mode
1. Functions
H-10
(1), (2) Function testing
(1) Testing of functioning of lamp (on/off) (2) Testing of functioning of ADF clutches function 2. Operation procedures (1) Testing the functioning of lamp (on/off) qAccess HELP mode H-10, and press the PRINT
key. \See page 235
: CCD T ES T
When the PRINT
key is pressed, the indicators will light.
wPress the STOP
(2) Testing of functioning of ADF clutches function qAccess HELP mode H-10, and press the PRINT
key. \See page 235
wSelect clutch A or B.
Clutch A
Press the DOCUMENT MODE SWITCH "TEXT". key and set to
Clutch B
Press the DOCUMENT MODE SWITCH "TEXT/PHOTOGRAPH". key and set to
ePress the TEST PRINT
key.
The clutch selected in Step 2) turns "ON".
rTo check the operation of the other clutch, proceed with Steps w) and e). tPress the STOP
249
chap.8
HELP mode
1. Functions
H-11
(1) Document darkness values and scanner test (for use in factory checks) 2. Operation procedures (1) Document darkness values and scanner test (for use in factory checks) qAccess HELP mode H-11, and press the PRINT
key. \See page 235
When the PRINT key is pressed, the lamp lights up and the document is conveyed to the "position for sensing document size". The sensed size is displayed as a 3-digit number ( 1 1 1 ) and the document is fed out.
111
Sensed size display
wSelect one of the items below, and follow the procedure given for it.
Display of darkness value for lightest part of document
a Use the DOCUMENT MODE SWITCH key to select the TEXT item. A value between 000 ("darkest" value) and 255 ("lightest" value) will be displayed.
Display of darkness value for darkest part of document (relative to lightest part, above)
a Use the DOCUMENT MODE SWITCH key to select the PHOTOGRAPH item. A value between 000 ("darkest" value) and 255 ("lightest" value) will be displayed.
ePress the STOP
250
chap.8
HELP mode
1. Functions
H-12
(1) Checking of shading memory, thermal head and main PCB unit synchronized signals
2. Operation procedures (1) Checking of shading memory, thermal head and main PCB unit synchronized signals qAccess HELP mode H-12, and press the PRINT
key. \See page 235 Display during check
00
Check of shading memory, and display of result a Press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT item. An "FFFF" result display indicates the memory is normal. Any other display indicates abnormality. Check result display
FFFF
Main PCB unit start signal Thermal head synchronized signal
Check of thermal head and main PCB unit synchronized signals a Press the DOCUMENT MODE SWITCH key as many times as needed to select the PHOTOGRAPH item. Two digits will be displayed. The first digit represents a count based on the thermal head synchronized signal, and the second a count based on the main PCB unit's start signal. These counts rise from 0 up to 7 , in increments of 1. The increments occur at intervals of approximately 1 second.
1 1
Check that the increment of both digits occurs at a rate of approximately 1 second per implement, so that over a period of 10 second, there is no marked difference between the two values. A marked difference indicates abnormality.
ePress the STOP
251
chap.8
HELP mode
1. Functions
H-13
(1) Checking of condition of sensors listed below:

Display of amount of light received by end mark sensor and master position sensor.
End mark sensor \See page 70 Master position sensor \See page 72
(2) Function testing of master feeding clutch
Master feeding clutch \See page 74
2. Operation procedures (1) Checking the condition of the listed sensors qAccess HELP mode H-13, and press the PRINT
key. \See page 235
wSelect the sensor below and follow the procedure accordingly.

S End mark sensor
To access this display, press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT/PHOTOGRAPH item. Display of presence/absence of the master on its travel path, as a numerical value. <Sensitivity adjustment of the end mark sensor> Adjust the sensitivity using the FUNCTION SWITCH key and SELECT key. Set the black level to "MAX-10". Make sure that the difference between black and white is "30" or larger.
S Master position sensor
11
Amount of light received by end mark sensor
aTo access this display, press the DOCUMENT MODE SWITCH key as many times as needed to select the TEXT item. Display of presence/absence of the master on its travel path, as a numerical value. " 0": Master present "63": Master absent key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
11
Amount of light received by master position sensor
ePress the STOP
252
chap.8
HELP mode
H-13
(2) Function testing of master feeding clutch qAccess HELP mode H-13, and press the PRINT
key. \See page 235
Press the TEST PRINT clutch once.
key. turns "ON" the master feeding
wPress the STOP
253
chap.8
HELP mode
1. Functions
H-14
(1),(2) Total counts
(1) Platemaking total counter display (2) Resetting of count of total plates made in user mode
Related HELP mode HELP mode H-19 \See page 259
2. Operation procedures (1) Platemaking total counter display qAccess HELP mode H-14, and press the PRINT
key. \See page 235
When the PRINT key is pressed, the total number of platemaking is displayed.
F11111111
Platemaking total counter
wPress the STOP
[F] = platemaking
(2) Resetting the count of total plates made in user mode qAccess HELP mode H-14, and press the PRINT
key. \See page 235
When the PRINT key is pressed, the current value for the count of total plates made in user mode will be displayed.
wPress the [=]
key and CLEAR
keys simultaneously, to
execute resetting. The resetting will be memorized in the battery PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
IMPORTANT :
111 SAVE 111
Do not turn off the power before the "SAVE" display has disappeared.
ePress the STOP
254
chap.8
HELP mode
1. Functions
H-15
(1) Function testing of ink motor
2. Operation procedures 1) Testing the functioning of the ink motor qAccess HELP mode H-15, and press the PRINT
key. \See page 235
: I NK MTR . T ES T
wPress and hold the TEST PRINT

for as long as the key is held down.
IMPORTANT :
key. The ink motor will run
Remember that ink will be delivered when the ink motor runs. Take any precautions necessary.
eRelease the TEST PRINT
key. The ink motor will stop.
rPress the STOP
255
chap.8
HELP mode
1. Functions
H-16
(1) Correction of platemaking start position during online platemaking
For Standards / Adjustment \See page 188 Related HELP mode HELP mode H-37 \See page 275 HELP mode H-52,H-57\See page 283 HELP mode H-53 \See page 285
2. Operation procedures (1) Setting correction of platemaking start position during online platemaking qAccess HELP mode H-16, and press the PRINT
key. \See page 235
wUse the [0] and [1] numeric keys to enter a 4-place binary value for
the desired correction amount. See the table below for 4-place binary values and the corresponding correction amounts.
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Rises by the set amount for the lower 3 digits Lowers by the set amount for the lower 3 digits Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
key. The correction amount will be memorized
in the battery PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
IMPORTANT :
111 SAVE 111
rPress the STOP
256
chap.8
HELP mode
1. Functions
H-17
(1) Cutter motor function testing
2. Operation procedure (1) Testing the cutter motor's functioning qAccess HELP mode H-17, and press the PRINT
key. \See page 235 key. The cutter
: CUT MTR . T ES T

motor will run for as long as the key is held down.
eTo stop the cutter motor, either release the FUNCTION SWITCH
key, or alter the cutter limit switch's condition from off to on.

run for as long as the key is held down.
key. The cutter motor will
tTo stop the cutter motor, either release the SELECT

alter the cutter limit switch's condition off to on.
key, or
yPress the STOP
IMPORTANT :
After executing the cutter motor test, be sure to return the cutter blade to the original position (operation side).
257
chap.8
HELP mode
1. Functions
H-18
(1) Function testing of roll-up motor
2. Operation procedures (1) Testing the functioning of the roll-up motor qAccess HELP mode H-18, and press the PRINT
key. \See page 235
: E J ECT M . TEST
key. The take-up
motor will rotate in the reverse direction (counterclockwise), so that the roller inside the master ejection box turns, for as long as the key is held down.
eTo stop the motor (and the roller), release the FUNCTION SWITCH
key.
rPress the STOP
258
chap.8
HELP mode
1. Functions
H-19
(1),(2) Total counts
(1) Printing total counter display (2) Resetting of count of total sheets printed in user mode
2. Operation procedures (1) 7-digit display of count of total sheets printed qAccess HELP mode H-19, and press the PRINT
key. \See page 235

"P"=Print
When the PRINT displayed.
key is pressed, the total number of print is
P . . 1111111
wPress the STOP
Printing total counter
(2) Resetting the count of total sheets printed in user mode qAccess HELP mode H-19, and press the PRINT
key. \See page 235
When the PRINT key is pressed, the current value for the count of total sheets printed in user mode will be displayed.
wPress the [=]
key and CLEAR
keys keys simultaneously,
to execute resetting. The resetting will be memorized in the battery PCB unit's EEPROM. During memorization, "SAVE" will be displayed.
IMPORTANT :
111 SAVE 111
ePress the STOP
259
chap.8
HELP mode
1. Functions
H-20
(1) Function testing of clump motor and clump position sensing (A/B/C mode position)
For Standards / Adjustment B mode \See page 167 For Standards / Adjustment A /C mode \See page 169 For description of operation \See page 80
2. Operation procedures (1) Testing the functioning of the clump motor and clump position sensing (A/B/C mode position) qAccess HELP mode H-20, and press the PRINT
key. \See page 235 key. The clump
: C L AMP M . T E S T
motor will rotate in the reverse direction (counterclockwise), opening out the clump, for as long as the key is held down.
eTo stop opening of the clump, release the FUNCTION SWITCH

key. (Alternatively, opening will stop automatically when the light beam of the A/C mode sensor (PS3) is restored).
key. The clump motor will
rotate in the regular direction (clockwise), closing the clump, for as long as the key is held down.
tTo stop closing of the clump, release the SELECT
key.
(Alternatively, closing will stop automatically when the light beam of the A/C mode sensor (PS3) is restored).
yPress the STOP
NOTE : Whether the clump is in the A, B or C mode position is determined by the B mode sensor and the A/C mode sensor in combination:
A mode position : When the light beam of both the B mode and A/C mode sensor is unobstructed. C mode position : When the light beam of both the B mode sensor is obstructed and that of the A/C mode sensor unobstructed. B mode position : When the B mode sensor senses edge, and the light beam of the A/C mode sensor is obstructed.
If the clump is not in the A mode position when the power is turned on, it will rotate to the B position and stop there.
260
chap.8
c HELP Mode Function and Operation Procedures Mode H-21 is not used
HELP mode
1. Functions
H-22
(1) Setting of lengthwise zoom factor correction amount for platemaking side
2. Operation procedures (1) Setting of lengthwise zoom factor correction amount for platemaking side qAccess HELP mode H-22, and press the PRINT
key. \See page 235
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Shortens by the set amount for the lower 3 digits. Lengthens by the set amount for the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

1 rank: 0.125%
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
261
chap.8
HELP mode
1. Functions
H-23
(1) Setting of photograph mode document sensing darkness
For Standards / Adjustment \See page 190 Related HELP mode HELP mode H-50 \See page 281
2. Operation procedures (1) Setting of photograph mode document sensing darkness qAccess HELP mode H-23, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

1 rank: 0.125%
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
262
chap.8
HELP mode
1. Functions
H-24
(1) Setting of reducing offset for reading longitudinal R/E scanner
2. Operation procedures (1) Setting of reducing offset for reading longitudinal R/E scanner qAccess HELP mode H-24, and press the PRINT
key. \See page 235
ABCD 0000 0001 0010 0011 1111 Set amount If help mode H-24 setting is required, HELP mode H-25 must be set to "0000". Item Setting Standard (initial value)
A:1 B:1 C:1 D:1
1 rank: 0.25%
Maximum
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
263
chap.8
HELP mode
1. Functions
H-25
(1) Setting of enlarging offset for reading longitudinal R/E of scanner
2. Operation procedures (1) Setting of enlarging offset for reading longitudinal R/E of scanner qAccess HELP mode H-25, and press the PRINT
key. \See page 235
ABCD 0000 0001 0010 0011 1111 Set amount If help mode H-25 setting is required, HELP mode H-24 must be set to "0000". Item Setting Standard (initial value)
A:1 B:1 C:1 D:1
Maximum
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
264
chap.8
HELP mode
1. Functions
H-26
(1) Compensation of document darkness white level in photograph mode
2. Operation procedures (1) Compensation of document darkness white level in photograph mode qAccess HELP mode H-26, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
265
chap.8
HELP mode
1. Functions
H-27
(1) Initialization of all HELP mode settings
2. Operation procedures (1) Initializing all the HELP mode settings qAccess HELP mode H-27, and press the PRINT
key. \See page 235
I N I T I AL I ZE
wPress the [=]
key. The adjustment and specification settings
of the HELP modes will be initialized. (But for the total counts (H14 and H-19), only the user mode values will be initialized.) While initialization is in progress, "SAVE" will be displayed.
IMPORTANT :
111 SAVE 111
ePress the STOP
IMPORTANT :
For the values after initialization, see the initialization values for each mode, and the HELP decals (on the inside of the front cover). After initialization, carry out the adjustment and specification setting operations for the various modes. Inappropriate settings will results in operational problems.
266
chap.8
HELP mode
1. Functions
H-28
(1) Setting of TAPE CLUSTER presence/absence, buzzer selection and KEYCARD COUNTER 2 specification
TAPE CLUSTER \See page 119
2. Operation procedures (1) Setting of TAPE CLUSTER presence/absence, buzzer selection and KEYCARD COUNTER 2 specification qAccess HELP mode H-28, and press the PRINT
key. \See page 235
ABCD 0*** 1*** *00* *01* *10* *11* ***0 ***1 1001 KEYCARD COUNTER 2 specifications Initial value Selecting buzzer. Item Whether there is a TAPE CLUSTER or not. Setting There is a TAPE CLUSTER. There is not a TAPE CLUSTER. Standard (Buzzer sounds) Buzzer does not sound when trouble occurs. Does not sound Does not sound KEYCARD COUNTER 2 No KEYCARD COUNTER 2
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
267
chap.8
HELP mode
1. Functions
H-29
(1) Adjustment of paper infeed amount

Feed amount is adjusted after cutter operation.
2. Operation procedures (1) Adjustment of paper infeed amount qAccess HELP mode H-29, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
268
chap.8
HELP mode
1. Functions
H-30
(1) Function checking
(1) Test pattern (all shading, sub-scanning direction zoom factor adjustment) platemaking and printing
For adjusting reduction / enlargement \See page 186
2. Operation procedures (1) Test pattern (all shading, poor image area checking, sub-scanning direction zoom factor adjustment) platemaking and printing qAccess HELP mode H-30, and press the PRINT
key. \See page 235

Test pattern 1
Test pattern 1 (all shading)
a Use the DOCUMENT MODE SWITCH PHOTOGRAPH item.
key to select the
Test pattern 3 (sub-scanning direction zoom factor adjustment)
a Use the DOCUMENT MODE SWITCH TEXT item.
key to select the
Test pattern 3
IMPORTANT :
Once this mode has been entered, it is not possible to switch to any other mode. To exit this mode, turn off the power.
ePress the PLATEMAKING rPress the STOP
key to implement platemaking/printing.
0sh t
1se t
269
chap.8
HELP mode
1. Functions
H-31
(1) Setting of number of pre-print sheets Use this to set a value for the number of pre-print sheets.
"Pre-print sheets" are extra sheets that are printed at the start of printing, without being added to the print count.
2. Operation procedures (1) Setting of number of pre-print sheets qAccess HELP mode H-31, and press the PRINT
key. \See page 235
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 Item 0 sheet(initial value) 1 sheet 2 sheets 3 sheets 4 sheets 5 sheets 6 sheets 7 sheets ABCD 1000 1001 1010 1011 1100 1101 1110 1111 8 sheets 9 sheets 10 sheets 11 sheets 12 sheets 13 sheets 14 sheets 15 sheets Item
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
270
chap.8
HELP mode
1. Functions
H-32
(1) Confidential safeguard function, selection of first print speed, setting of master ejection error sensing
2. Operation procedures (1) Confidential safeguard function, selection of first print speed, setting of master ejection error sensing qAccess HELP mode H-32, and press the PRINT
key. \See page 235
ABCD 0*** 1*** *0** *1** **0* **1* ***0 ***1 1000 Initial value Item Confidential safeguard function Selecting the first print speed. /Selecting the print speed for the first sheet after plate making is completed. Master mis-ejection detection Not used. Not set Set 1st-speed (about 45 rpm) JOG speed (about 15 rpm) Yes No Setting
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
271
chap.8
HELP mode
1. Functions
H-33
(1) Compensation of document darkness white level in text mode
2. Operation procedures (1) Compensation of document darkness white level in text mode qAccess HELP mode H-33, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
272
chap.8
c HELP Mode Function and Operation Procedures Mode H-34 is not used
HELP mode
1. Functions
H-35
(1) Scanner leading edge sensing position adjustment
2. Operation procedures (1) Scanner leading edge sensing position adjustment qAccess HELP mode H-35, and press the PRINT
key. \See page 235
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Moves to the left by the set amount of the lower 3 digits. Moves to the right by the set amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
273
chap.8
HELP mode
1. Functions
H-36
(1) Scanner widthwise (operation side) sensing position adjustment
2. Operation procedures (1) Scanner widthwise (operation side) sensing position adjustment qAccess HELP mode H-36, and press the PRINT
key. \See page 235
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Moves toward you by the set amount of the lower 3 digits. Moves backward by the set amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
274
chap.8
HELP mode
1. Functions
H-37
(1) Adjustment of platemaking start position when scanner is used
2. Operation procedures (1) Adjustment of platemaking start position when scanner is used qAccess HELP mode H-37, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
275
chap.8
c HELP Mode Function and Operation Procedures Modes H-38,H-39 are not used.
HELP mode
1. Functions
H-40
(1) Correction of outline highlight when scanner is used, setting platemaking area (sub-scanning direction)
2. Operation procedures (1) Correction of outline highlight when scanner is used,setting platemaking area (sub-scanning direction) qAccess HELP mode H-40, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ABCD 0*** 1*** **00 **01 **10 0000 Initial value Photograph mode Item Platemaking area (Sub-scanning direction) Setting Selected document size 350mm Normal Dark Light
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
276
chap.8
HELP mode
1. Functions
H-41
(1) Automatic initialization of the control panel setting, setting of repeat count display
2. Operation procedures (1) Automatic initialization of the control panel setting, setting of repeat count display qAccess HELP mode H-41, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ABCD 0*** 1*** *0** *1** **0* **1* 1000 Item Automatic initialization of the control panel setting Setting No automatic iniialization Initialized in about 2 minutes
Not used Repeat display of count Count repeat display No repeat display of count Initial value
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
277
chap.8
HELP mode
1. Functions
H-42
(1) Setting of paper selection specification, setting platemaking area (main-scanning direction)
2. Operation procedures (1) Scanner leading edge sensing position adjustment, setting platemaking area (main-scanning direction) qAccess HELP mode H-42, and press the PRINT
key. \See page 235
ABCD 00** 10** *0** *1** **00 **01 **10 **11 0000 Initial value Paper selecting with the power ON Item Paper selecting specifications (A/B size) Paper selecting specifications (inch) Platemaking range (main-scanning direction) B4/A4/B5/A5 10914/LTLG/ST/POST Selected size 250mm B4/10914 A4/LTLG B5/ST A5/POST Setting
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
278
chap.8
HELP mode
1. Functions
H-43
(1) Offset value for the thermal head drive energy
2. Operation procedures (1) Offset value for the thermal head drive energy qAccess HELP mode H-43, and press the PRINT
key. \See page 235
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 1001 1010 1011 1100 1101 1110 1111 Setting Normal (initial value) Light 1 Light 2 Light 3 Light 3 Light 3 Light 3 Light 3 Dark 1 Dark 2 Dark 3 Dark 3 Dark 3 Dark 3 Dark 3
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
279
chap.8
HELP mode
1. Functions
H-44
(1) Setting of thermal head resistance ranking
2. Operation procedures (1) Setting of thermal head resistance ranking qAccess HELP mode H-44, and press the PRINT
key. \See page 235
ABCD 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111 Resistance 3825-3908 3909-3993 3994-4077 4078-4162 4163-4246 4247-4330 4331-4415 4416-4499 4500-4583 4584-4668 4669-4752 4753-4837 4838-4921 4922-5005 5006-5090 5091-5175
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
280
chap.8
c HELP Mode Function and Operation Procedures Mode H-45, 46, 47, 48 and 49 are not used
HELP mode
1. Functions
H-50
(1) Setting of text mode document sensing darkness
2. Operation procedures (1) Setting of text mode document sensing darkness qAccess HELP mode H-50, and press the PRINT
key. \See page 235
Display 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Maximum Set amount Item Setting Lighter by the set amount for the lower 3 digits Darker by the set amount for the lower 3 digits Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
key. The HELP mode selection display will reappear.
a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
281
chap.8
HELP mode
1. Functions
H-51
(1) Setting of darkness for test pattern platemaking

Use this to adjust the platemaking darkness for area q of HELP mode H-30's test pattern 2.
2. Operation procedures (1) Setting of darkness for test pattern platemaking qAccess HELP mode H-51, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

Sign flag
Display 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 *110 *111 Set amount
Item
Setting Lighter by the set amount for the lower 3 digits Darker by the set amount for the lower 3 digits Standard (initial value)
Maximum
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
282
chap.8
HELP mode H-52, H-57

1. Functions (1) Setting of online conditions
Related HELP mode HELP mode H-16 \See page 256 HELP mode H-53 \See page 285
Use H-52 to set I/F switching (auto/manual) and online platemaking mode. Use H-57 to select data transmission speed (time for scanning of 1 line) for online platemaking.
2. Operation procedures (1) Setting of online conditions qAccess HELP mode H-52, and press the PRINT
key. \See page 235

H-52
A:1 B:1 C:1 D:1
H-52 00** 11** **0* **1* ***1 ***0 ***1 ***0 0000
H-57
Item
Setting Correction amount display
I / F auto / manual Manual setting Auto(standard) DP-10 test pattern 0*** 0*** 1*** 1*** 0000 Line scanning speed Standard DP-10 test pattern only 1.6m sec / line 2.0m sec / line(standard) 3.2m sec / line 4.0m sec / line Factory setting
ePress the [=]
IMPORTANT :
111 SAVE 111
283
chap.8
HELP mode H-52, H-57
key. rPress the STOP tTo also select the data transmission speed (time for scanning of 1 line), carry out this step and the following 2 steps: Access HELP mode H-57, and press the PRINT key.
H-57:Line scanning speed
yUse the [0] and [1] numeric keys to enter a new 4-place binary value. See the table in w above for 4-place binary values and the
corresponding settings.
A:1 B:1 C:1 D:1
uPress the [=]
IMPORTANT :
111 SAVE 111
iPress the STOP
284
chap.8
HELP mode
1. Functions
H-53
(1) Adjustment of widthwise (operation side) platemaking start position for online platemaking
Related HELP mode HELP mode H-52,57 \See page 283 HELP mode H-16 \See page 256
2. Operation procedures (1) Adjustment of widthwise (operation side) platemaking start position for online platemaking qAccess HELP mode H-53, and press the PRINT
key. \See page 235
ABCD 0*** Sign flag 1*** *000 *001 *010 *011 *100 *101 ***1 *111 Maximum Set amount Item Setting Moves toward you by the set amount of the lower 3 digits. Moves backward by the set amount of the lower 3 digits. Standard (initial value)
A:1 B:1 C:1 D:1

ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
285
chap.8
c HELP Mode Function and Operation Procedures Mode H-54 is not used.
HELP mode
1. Functions
H-55
(1) Setting of ink check at printing start, cutting operation mode for master cutting, and interlocks
2. Operation procedures (1) Setting of ink check at printing start, cutting operation mode for master cutting, and interlocks qAccess HELP mode H-55, and press the PRINT
key. \See page 235
ABCD 0*** 1*** *0** *1** **0* **1* ***0 ***1 0100 Item Setting of ink check, that triggers ink replenishment if no ink is detected at printing start Selection of cutter operation mode Interlock: emergency stop if top cover or ejection box open Not used Initial value Ink check No ink check 1 stroke = one-way motion 1 stroke = reciprocating motion Activated Deactivated Setting
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
286
chap.8
HELP mode
1. Functions
H-56
(1) Setting for selecting manipulation language
2. Operation procedures (1) Setting for selecting manipulation language qAccess HELP mode H-56, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ABCD 0000 0001 0010 0011 0100 0101 0110 Manipulation language Japanese English German Italian Spanish French
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
287
chap.8
c HELP Mode Function and Operation Procedures Mode H-57 (refer to H-52) Mode H-58, H-59, H-60 are not used
HELP mode
1. Functions
H-61
(1) Selection of LCD specification
2. Operation procedures (1) Selection of LCD specification qAccess HELP mode H-61, and press the PRINT
key. \See page 235
Display 0 0 ** 0 1 ** 1 0 ** 1 1 ** 0 0 0 0 Factory setting Selection of LC display specifications Item Setting Japanese: Duplo Japanese: Other
English Other foreign language
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
288
chap.8
c HELP Mode Function and Operation Procedures Mode H-62, H-63 are not used
HELP mode
1. Functions
H-64
(1) Buzzer (tone) setting
2. Operation procedures (1) Buzzer (tone) setting qAccess HELP mode H-64, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

Sign flag
ABCD 0*** *000 *001 *010 *011 Set amount Sign flag
Item Tone setting
Setting
Standard (initial value : 0000) Tone adjusting Maximum
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
289
chap.8
c HELP Mode Function and Operation Procedures Mode H-65 is not used.
HELP mode
1. Functions
H-66
(1) Setting: clump opening/closing timing of when a master is attached; paper feed sensor (loop sensor) ON/OFF; Paper size mode (long type)
2. Operation procedures (1) Setting: clump opening/closing timing of when a master is attached; paper feed sensor (loop sensor) ON/OFF; Paper size mode (long type) qAccess HELP mode H-66, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1
ABCD 0*** 1*** *0** *1** *10* *11* ***0 ***1 0000
Item Setting for master clump opening/closing timing for master attachment Setting of paper feed sensor (loop sensor) ON/OFF Not used Paper size mode (long type) At shipment OFF ON C mode
Setting master feed out C mode B mode B mode
master feed out OFF ON
ePress the [=]
IMPORTANT :
111 SAVE 111
Do not turn off the power before the "SAVE" display has disappeared. key. The HELP mode selection display will reappear. a To exit the HELP mode : Turn the power switch OFF. a To access another HELP mode : Enter the desired mode number using the numeric keys.
rPress the STOP
290
chap.8
HELP mode
1. Functions
H-67
(1) Setting of paper feed length
2. Operation procedures (1) Setting of paper feed length qAccess HELP mode H-67, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1

ABCD 0001 0000 1110 1111 Smaller the arching dimension Set amount Item Setting Larger the arching dimension
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
291
chap.8
HELP mode
1. Functions
H-68
(1) Setting of paper feed timing
2. Operation procedures (1) Setting of paper feed timing qAccess HELP mode H-68, and press the PRINT
key. \See page 235
ABCD 0001 0000 1110 1111 Smaller the paper feed timing Set amount Item Setting Larger the paper feed timing
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
292
chap.8
HELP mode
1. Functions
H-69
(1) Setting of model
2. Operation procedures (1) Setting of model qAccess HELP mode H-69, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1
ABCD 0000 0001 0011
Item DP-23S Setting of model DP-21L DP-21S
Setting
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
293
chap.8
HELP mode
1. Functions (1) Option setting 1
H-70
2. Operation procedures (1) Option setting 1 qAccess HELP mode H-70, and press the PRINT
key. \See page 235
A:1 B:1 C:1 D:1
ABCD 0000 0001
Item Normal
Setting
Option setting 1
KEYCARD COUNTER 4
IMPORTANT :
*Add a DIP switch to the battery board. Dip switch setting 1, 0, 0
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
294
chap.8
c HELP Mode Function and Operation Procedures Mode H-71, H-72,H-73, H-74 and H-75 are not used
HELP mode
1. Functions
H-76
(1) Document darkness correction for text/photograph mode
2. Operation procedures (1) Document darkness correction for text/photograph mode qAccess HELP mode H-76, and press the PRINT
key. \See page 235
ABCD 00** 01** 10** 11** Setting Item Setting Normal (initial value) Slightly lighter Slightly darker Much darker
A:1 B:1 C:1 D:1
ePress the [=]
IMPORTANT :
111 SAVE 111
rPress the STOP
295
MEMO
296
Chapter 9
Others
z Electrical Parts Layout and Their Functions ...........298 (1) Switch / Clutches .................................................298 (2) Sensors ..................................................................299 (3) Lamps / Motors .....................................................300 (4) PCB unit................................................................301 (5) Connector VR/LED Layout and Functions..........302 x Overall Wiring Layout ................................................305
9
297
chap.9
z Electrical Parts Layout and Their Functions

(1) Switches/Clutches
12 4 15 14 6 11 3 1 10 13
2 7 9 5
23S0267
8
Item No. 1 2 3 4 Microswitch/switch 5 6 7 8 Push switch 9 10 11 12 Clutch 13 14 15 Functions Whether the drum is set or not is detected. Opening and closing of the front cover is detected. Whether the master ejection core is set or not and full or not is detected. ADF cover open/closed detection. Master cover open/closed detection Opening and closing of the top cover is detected. Elevator lower limit switch Power switch Paper/master feed elevator descent switch JOG switch (drum rotator switch) Master feeding clutch ADF clutch A ADF clutch B Paper feed clutch Paper ejection clutch DP-23S
298
chap.9
(2) Sensors
5 6 13 11 10 8 3 4 1 2 14 17 18 20
15
16
12
19
23S0268
Item
No. 1 2 3 4 5 6
Functions Weather the document is placed or not is detected. Document JAM is detected. Master clump opening and closing lever A/C mode is detected. Master clump opening and closing lever B mode is detected. Drum home position and JAM detection position are detected. Master attachment/detachment position is detected. Main motor encoder sensor. Press roller ON and OFF is detected. Paper/master feed elevator top limit detection. Print position limit of the print position is detected. Center position of the print position adjustment is detected. Weather the paper is placed or not is detected. LPU escape timing is detected. DP-23S Leading edge of paper is detected. Master position is detected. Loop is detected. Photo-emitting of the master ejection and JAM detection sensor. Master is detected at the inlet of the master ejection box. Paper on the paper delivery side is detected. Detection of paper on paper ejection side.
Microsensor
7 8 9 10 11 12 13 14
Photointerrupter
15 16
Master ejection sensor photo-emitting Master ejection sensor photo-emitting Jam sensor photo-receiving Jam sensor photo-emitting
17 18 19 20
299
chap.9
(3) Lamps/Motors
1 10 5 8 12 4 7 6
13 9
2 11 3
23S0269
Item Lamp Thermal head
No. 1 2 3 4 5 6 Document lamp Thermal head Main motor Paper feed tray elevator motor
Functions
Master clump opening/closing lever motor Roll-up motor Cutter motor Print position adjusting motor Ink pump motor Scanner stepping motor Plate making stepping motor Guide roller drive motor DP-23S Paper ejection fan
Motor
7 8 9 10 11 12
Fan motor
13
300
chap.9
(4) PCB unit

6 2 7 1
11 8 10
Item CCD PCB unit Inverter PCB unit Control panel PCB unit Ink detection PCB unit End mark sensor PCB unit Main PCB unit Battery PCB unit Motor PCB unit Drive PCB unit Regulated power supply Mini drive PCB unit DP-23S No. 1 2 3 4 5 6 7 8 9 10 11 Reading the picture image. Lamp lights up. Control panel key, display. Detecting Ink amount in the drum. Detection of master presence on master feed travel path, and end mark. Processing the image and controlling the machine on the whole. Keeping the total counter and HELP information. Controlling the main motor. Driving the motor. Supplying with DC power supply. Controlling the LPU (Long Paper Unit). Functions
23S0270
301
chap.9
(5) Connector VR/LED Layout and Functions
1) CCD PCB unit

CN 1 CCD
3) Control Panel PCB unit

CN 1
4) Ink Detection PCB unit
VR / LED VR LED
Function VR 1 * Adjusting the ink detection sensitivity. Lights up when ink OK is detected. CN 1
CN 1
2) Inverter PCB unit
CN 2
LED
IMPORTANT : * : Adjusted at the factory. Do not change.
302
chap.9
5) End Mark Sensor PCB unit

CN 1
6) Main PCB unit
CN 4 CN 5
CN 6 CN 7 CN 8 SW 1 u 25 CN 11 u 26 u 27 u 12 CN 9 CN 1 CN 2 CN 10
CN 3 (24P)
u 35
u5
CN 1 (32P)
CN 2 (30P)
CN 13
CN 14 CN 12
7) Battery PCB unit (EEPROM PCB)
303
chap.9
8) Main Motor PCB unit

VR VR 1 VR 2 Function Pre-stop speed adjustment. JOG speed adjustment.
FUSE (250V 10A) VR 1 CN 4
VR 2 CN 1
9) Drive PCB unit

FUSE (125V 10A) Mini drive PCB unit DP-23S
CN 7 CN 6
CN 5
CN 2 CN 8 CN 4 CN 5 CN 9 FUSE (125V 5A) CN 1 VR1
10) Regulated power supply
CN 3
304
CN 3
CN 2
CN 1
CN 3
chap.9
x Overall Wiring Layout
305
Reproduction prohibited
1st printing : February 2000 2nd printing : December 2000
Issued by : DUPLO SEIKO CORPORATION

PRINTED IN JAPAN

dp21l, 21s & 23s Maintenance Ver2

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dp21l, 21s & 23s Maintenance Ver2

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SERVICE MANUAL

DP-23S DP-21S DP-21L

DUPLO SEIKO CORP.

Copyright 2000 DUPLO SEIKO CORPORATION All Rights Reserved

D Using the service manual

Examples of pictorial symbols

2. Cautions for installation work

} Use power supply meeting these requirements

} Use power supply meeting these requirements

3. Cautions for maintenance, inspection and servicing

DLocations of warning stickers

Parts No. L1-T3060 L5-T3020 M7-T3030 L1-T3090

Name Warning Sticker 1 Warning Sticker 2 Warning Sticker 3 Caution Sticker

Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9

Description of the Operation

z DUPRINTER Installation Instructions ....................196

Description of the Operation

z Troubleshooting Guide............................................212 x Error Display ............................................................228

z Electrical Parts Layout and Their Functions.........298 x Overall Wiring Layout..............................................305

1 Option ...........................................................................52 1. DUPRINTER Option .................................................52 (1) TAPE CLUSTER 4 .............................................52

uMemory function Allows 9 sets of memory settings.

Min. 100 mm x 148 mm

* Specifications are subject to change without notice.

Master ejection box

Drum unit Feeder roller Paper Paper stripper finger Ink

Press roller Paper sepatator unit

Paper ejection belt Fan unit

Duplo Direct Print System

KEYCARD COUNTER 4 TAPE CLUSTER 4

Cabinet (Printer stand)

, Part Names and Their Functions

,Part Names and Their Functions

Cabinet (Printer stand) Caster locks

, Part Names and Their Functions

Master set lever

Document receiving tray (Top cover)

Master cover release lever

Ink pack holder release lever

Drum securing lever

, Part Names and Their Functions

Master ejection core

Master ejection box release lever

Master ejection box lid release lever Master ejection box

Paper stacker guides

JOG switch (Drum rotator switch)

, Part Names and Their Functions

, Part Names and Their Functions

2. Sectional (structural) view of the machine

, Part Names and Their Functions

, Part Names and Their Functions

Name STOP key

ALL CLEAR key

, Part Names and Their Functions

Name Print count Sets

Printing position adjustment Printing speed adjustment Test print key

Input the number of prints and the number of sets

0 Error Messages and Corrective Action

0Error Messages and Corrective Action

Cause and corrective action

ROLL - MASTER END

EXCHG. EJECT - CORE

SET PRINT PAPER