DETAILED DESCRIPTIONS MANUAL 1. OVERVIEW ... 1 1.1 GENERAL ... 1 1.1.1 CONFIGURATION ... 1 1.1.2 FEATURES ... 2 1.1.3 COMPARISON TO D093/D094 ... 3 D124 and D093/D094 Compared ... 3 1.1.4 SIMILARITIES WITH PREVIOUS MACHINES ... 4 Horizontal Carriage Movement During Printing ... 4 Vertical Paper Feed... 5 Maintenance Unit ... 6 Ink Supply ... 7 Waste Ink Collection... 8 DRESS Sensor ... 9 1.1.5 SOME UNIQUE FEATURES OF D124 10 Main Machine Stand and Scanner Stand ...10 Front Cover Switches ...10 Ink Level Detection ...11 Cutter ...11 Paper Feed Control ...12 Improved Productivity ...13 1.2 GENERAL LAYOUT ...14 1.3 MAIN UNIT LAYOUT ...16 1.4 MOTORS, CLUTCHES, AIR RELEASE SOLENOID ...18 1.5 SCHEMATIC DIAGRAM ...21 1.6 ORIGINAL PATH, PAPER PATH SENSORS ...22 1.7 GENERAL OPERATION SEQUENCE ...26 1.7.1 1 POWER ON ...26 1.7.2 2 SCANNING ...27 1.7.3 3 PAPER FEED ...28 1.7.4 4 PRINTING...30 1.7.5 5 CUTTING ...32 1.7.6 6 PAPER EXIT AND JOB END ...33 1.8 SERVICE PRECAUTIONS ...34 1.8.1 HANDLING ROLLERS...34 1.8.2 PERMANENT (PAINT-LOCKED) SCREWS ...35 Main Frame Screws ...35 Right Plate Screws ...35 Maintenance Unit Base Screws ...36 Solenoid Bracket Screw ...37 Main Carriage Screws ...37 Platen Plate Guide Rod Screws ...38Sensor and Temperature/Humidity Sensor Bracket ...38 1.9 PM PARTS...39 1.9.1 PM PARTS TABLE ...39 PM Parts and Estimated Service Life ...39 2. SCANNER UNIT ... 40 2.1 SCANNER LAYOUT ...40 2.1.1 SIDE VIEW ...40 2.1.2 FRONT VIEW ...42 2.2 ORIGINAL WIDTH DETECTION ...43 2.3 SCANNING ...45 2.3.1 ORIGINAL FEED, EXIT SEQUENCE ...45 2.3.2 AUTO IMAGE DENSITY CORRECTION ...46 2.3.3 SCANNING AREA ...47 2.3.4 SCAN MAGNIFICATION CORRECTION ...48 2.4 ORIGINAL DRIVE MECHANISM ...49 2.4.1 SCANNING MOTOR, ROLLERS ...49 2.4.2 ORIGINAL FEED SPEED ...50 Black-and-White Standard for Copying ...51 Black-and-White Standard for Scan to File ...51 2.5 SCANNING MECHANISM ...52 2.5.1 CIS STRUCTURE...52 2.5.2 PRINTED IMAGE...53 2.6 LONG ORIGINAL OR SPECIAL ORIGINAL WITH CARRIER SHEET ...54 3. IMAGE PROCESSING ... 55 3.1 IMAGE FLOW ...55 3.1.1 COPY JOB IMAGE DATA FLOW ...55 3.1.2 SCAN JOB IMAGE DATA FLOW ...56 3.1.3 PRINT JOB IMAGE DATA FLOW ...56 3.2 COPY MODE IMAGE PROCESSING ...57 3.3 PRINT MODE IMAGE PROCESSING ...59 3.4 COPY RESOLUTION: COPY JOBS AND PRINT JOBS...60 3.4.1 COPY JOBS ...60 3.4.2 PRINT JOBS ...61 3.5 IMAGE TROUBLESHOOTING ...63 Internal Test Patterns ...63 IPU Test Patterns ...63 4. PAPER FEED AND EXIT ... 64 4.1 OVERVIEW ...64 4.2 ROLL UNIT OPERATION ...65 4.2.1 GENERAL OPERATION OF ROLL FEEDER UNITS ...65 4.2.2 ROLL FEED MECHANISM ...66 4.2.3 INITIALIZING THE FIRST PAPER ROLL ...67 4.2.4 INITIALIZING THE SECOND PAPER ROLL ...71 4.2.5 ROLL REWINDING FOR REMOVAL...72 From the registration standby position: ...72 From the paper standby position: ...73 4.2.6 ROLL END ...74 4.3 MAIN UNIT PAPER FEED ...75 4.3.1 REGISTRATION ROLLER, EXIT ROLLER ...75 4.3.2 VERTICAL FEED MECHANISM ...76 4.4 REMAINING PAPER DETECTION ...78 5-Step Operation Panel Display ...80 4.5 PAPER TRANSPORT FAN...81 4.5.1 GENERAL OPERATION...81 4.5.2 TRANSPORT FAN DUTY ADJUSTMENT ...82 4.5.3 NORMAL PAPER, RECYCLED PAPER ...84 4.5.4 TRANSLUCENT PAPER ...84 4.6 DETAILED DESCRIPTION OF PAPER FEED SEQUENCE ...86 4.6.1 PAPER FEED LAYOUT ...86 4.6.2 OPERATION SEQUENCE WHEN THE FIRST ROLL IS SET ...87 4.6.3 PAPER SKEW CORRECTION ...88 4.6.4 OPERATION SEQUENCE WHEN THE SECOND ROLL IS SET ...91 4.7 CUTTING ...92 4.8 BYPASS FEED ...93 5. INK SUPPLY ... 95 5.1 OVERVIEW ...95 5.2 INK CARTRIDGE ...97 5.3 INK SUPPLY MECHANISM ...99 5.4 CONTROLLING INK SUPPLY TO THE SUB TANKS ...101 5.4.1 THE OCFS SYSTEM ...101 5.4.2 CONTROLLING INK SUPPLY DURING PRINTING ...103 5.4.3 AIR DETECTION AND AIR PURGING ...103 5.4.4 AIR PURGE MECHANISM ...104 5.4.5 AFTER AIR PURGING ...105 6. PRINTING ... 106 6.1 PRINTING DRIVE MECHANISM ...106 6.2 CARRIAGE UNIT ...107 6.3 PRINT HEAD UNIT ...110 6.4 PRINT HEAD ...112 6.5 DRESS SENSOR ...113 6.6 TEMPERATURE MONITORING...116 6.7 PRINT HEAD HEIGHT ADJUSTMENT ...118 6.7.1 HEIGHT ADJUSTMENT MECHANISM ...118 6.7.2 RAISING AND LOWERING THE PRINT HEADS ...119 6.8 MAINTENANCE UNIT...122 6.8.1 OVERVIEW ...122 6.8.2 CAPPING/UNCAPPING ...123 K1 Print Head Uncapping/Capping...123 K2, C, YM Print Head Uncapping/Capping ...124 6.8.3 PRINT HEAD CLEANING CYCLE ...126 Step 2: Raising the Suction Cap ...127 Step 3: Suction ...128 Step 4: Scraping and Wiping ...129 6.8.4 MANUAL PRINT HEAD CLEANING AND FLUSHING ...130 6.8.5 AUTOMATIC DOWNTIME CLEANING...130 Maintenance Cycles Based on Idle Time ...131 Approximate Times Required for Cleaning ...131 6.8.6 AUTOMATIC MIST CLEANING ...132 6.9 WASTE INK COLLECTION ...133 6.9.1 INK COLLECTOR TANK ...134 6.9.2 RIGHT INK SUMP ...136 6.9.3 LEFT INK SUMP ...137 7. PRINT HEAD CLEANING AND ADJUSTMENT ... 138 7.1 MAINTENANCE MENU ADJUSTMENTS ...138 7.2 NOZZLE CHECK, CLEAN AND FLUSH PRINT HEADS ...140 7.2.1 NOZZLE CHECK ...140 7.2.2 CLEAN PRINT HEADS ...142 7.2.3 FLUSH PRINT HEADS ...145 7.2.4 WHEN PRINTING CANNOT BE RESTORED... ...146 7.3 AUTO ADJUST HEAD POSITION ...147 7.4 MANUAL ADJUST HEAD POSITION ...150 7.5 ADJUST PAPER FEED ...153 7.6 ADJUST PRINT POSITION ...156 8. ELECTRICAL COMPONENTS ... 158 8.1 BOARD LAYOUT ...158 8.1.1 SIB ...158 8.1.2 OPERATION PANEL BOARDS (INSIDE OPERATION PANEL) ...159 8.1.3 STANDARD BOARDS (REAR) ...160 8.1.4 OPTION BOARDS (REAR) ...161 8.1.5 MCU, IPU ...162 8.1.6 PSU ...163 8.1.7 GW CONTROLLER BOARD ...164 8.2 DESCRIPTION OF ELECTRICAL COMPONENTS ...165