Dolev 4press - Assemblies
Loading/Unloading System

• Detectors and switches
• Encoders
• Loading/Unloading Roller Pressure Adjustment (01 Apr 03)
• Loading Motor
• Unloading Axis
• Unloading/Take Motor
• Cutter Motor Assembly
• Unloading Guide / Selector
• Cassette Motor
• Disassembly of the Drive Unloading Roller
• Disassembly of the Unload Roller (The Outer Roller)
• Rocker - Disassembly & Assy
• Inner Loading Roller (Driving Roller) - Disassembly
• Mouth Assembly

• FCO 21611 Unloading light seal (memo)
• Film Stuck in Guide (memo)
• 4 mil & 7 mil Upgrade Kit (16-Mar-98) (memo)

Detectors and switches

Detectors

Film loading and unloading is performed using three (3) detectors:

Film Loading/Unloading Steps

Loading and unloading steps are performed in a set sequence, during which time standard status messages are displayed on the control monitor. These status messages keep the Operator informed as to the exact state of the process, and can be used to isolate film loading or unloading problems.

Film Loading Sequence

1. The Loading Cassette is placed in the Imagesetter. The film is trimmed and the Loading Drawer is closed.
   When the Loading Drawer is closed, the loading rollers inside the Imagesetter are engaged to receive the new film.
2. The control monitor displays the Media Information table, which stores Loading Cassette memory information. If necessary, the current parameters are entered.
   The Dynamic Optics Carriage is moved to the center of the film. (The centering calculation is determined from Film Width parameter in the Media Information table.) The film bow is used to deflect the film during film first loading.
3. A First Load is performed and film is advanced through the film rollers. Both Load and Take motors are activated to advance the film from the Loading Cassette completely into the Imagesetter drum.
4. An Attach is performed to apply the required tension to the film inside the drum. This is accomplished by reversing the Take motor slightly, while advancing the Load motor. The two motors then work against each other to create the proper film tension. (Tension is maintained throughout the exposure process by keeping both Load and Take motors activated.)
5. Exposure takes place. During exposure, film tension is reduced slightly.
6. Following an exposure, a Relief is performed to enable film movement. A Width End Margin length is then advanced through the drum.
7. When another exposure follows in the same batch, a Width Home Margin length is advanced through the drum. Before exposure begins, an Attach is performed to reapply tension to the film inside the drum.

Film Unloading Sequence

Unloading can be either to the Accumulating Cassette or to an Inline Processor (ILP).

1. The last exposure is completed.
2. A Relief is performed to relieve film tension in the Imagesetter drum. This is accomplished by advancing the Take motor slightly, while the Load motor is backed off.
3. An Advance is performed. The length of exposed film plus a Width End Margin length is advanced through the drum. Either the Accumulating Cassette or Conveyor motors are activated, according to the configuration. If the Accumulative Cassette is being used, a Leader Size length is added to the film advance.
4. A Cut is performed, using the Cutter motor.
5. If the Accumulating Cassette is being used, the exposed film is collected and the Unloading Drawer is opened.

Unloading to Accumulating Cassette

The following figure depicts the film unloading sequence to the Accumulating Cassette. Before and after each file is exposed, Home Margin and End Margin lengths are advanced through the Imagesetter drum. Film is collected continuously by the Accumulating Cassette. After the last file in the batch is exposed, a Leader Size film length is advanced and a Cut is performed.

Unloading to Accumulating Cassette
Click to see the full size

Unloading to Inline Processor (ILP)

The following depicts the film unloading sequence to the Inline Processor. Before each file is exposed a Width Home Margin length is advanced through the Imagesetter drum. After each file, a Width End Margin length is advanced, and a Cut is performed. Film is collected by the ILP.

Unloading to Inline Processor (ILP)
Click to see the full size

Encoders

Accumulator Encoder Assembly

Encoder - Assembly

Film loading and unloading is performed using three (3) encoders:

Loading Motor

• FCO 21629 New Loading, Unloading and Cutter Motors (memo)
• FCO 21348 Replacing the Load/Unload Motors Bases & Couplings (memo)

Loading Cassette

At front right of Imagesetter drum. Initially loads film from the Loading Cassette into the Imagesetter drum, advances film between exposures, and provides required film tension in drum. Used also to reverse film back into Loading Cassette whenever the drum is emptied.

Loading Axis

Loading Axis

Unloading Axis

• Loading Unloading Forces (memo)
• Rear Guides Drawing (memo)

Unloading/Take Motor

• See FCO 21629 New Loading, Unloading and Cutter Motors (memo)
• See FCO 21348 Replacing the Load/Unload Motors Bases & Couplings (memo)

At rear right of Imagesetter drum. Advances film between exposures and provides required film tension in drum.

Cutter Motor Assembly

• See FCO 21629 New Loading, Unloading and Cutter Motors (memo)
• Cutter Problems (memo)
• Cutter Hits the Film Out Detector Screws ( ECO 23125 ) (memo)

Film Path Selector

At rear right of Imagesetter, below drum. Drives the film cutter back and forth on its chain.

Cassette Motor

Unloading Cassette

• Cassette Motor Interlock (memo)

Accum. Cassette Motor or Conveyor Motor

On right side of Unloading Drawer. Draws film into the Accumulating Cassette. Between the Imagesetter and the Inline Processor (ILP). Draws film into Inline Processor.

Disassembly of the Drive Unloading Roller

1. Unload the film from the Imagesetter.
2. Remove the Loading Cassette.
3. Power off the imagesetter.
4. Remove the unloading Motor:
   1. Disconnect the motor cable.
   2. Release the two screws that attached the motor bracket to the right flange.
   3. Remove the motor. Make sure that the inner part of the coupling motor will not fall down.
   4. Disconnect the part of the coupling from the roller edge.
5. Release the two attachment springs. The unload outer roller should not be attached to the drive roller.
6. Open the rear cover.
7. Remove the two center supports. The one of the drive roller and the one of the outer roller.In order to remove the inner center support the on-line film guides and the two funnel guides should be remove. Each film guide is supported by two screws one from each side. Only release is needed in order to remove the guide.
8. Remove the inner film guide.
9. Release the roller bearing bushing ( two 4/40 screws ).
10. Remove the bushing, spring washer and flat washer. ( on the left side )
11. Remove the roller from the left side of the imagesetter.

Disassembly of the Unload Roller (The Outer Roller)

1. Unload the film from the Imagesetter.
2. Remove the Loading Cassette.
3. Power off the imagesetter.
4. Remove the Encoder finger. Use two keys, one inside the roller special hole and one inside the finger hole. Make sure that the rubber ring on the encoder wheel will not damage during this removal.
5. Remove the black wheels from both sides.
6. Open the rear cover.
7. Remove the roller center support.
8. Release the inner film guide. The two brackets on both sides of the guide supports the outer film guide.
9. Remove the outer film guide. (6 4/40 screws ).
10. Release the roller bearing bushing (two 4/40 screws ).
11. Remove the bushing, spring washer and flat washer (on the right side).
12. Remove the roller from the right side of the imagesetter.

Rocker - Disassembly & Assy

Rocker - Load/System

Disassembly

1. Unload film from the imagesetter
2. Remove the Loading Cassette
3. Power off the Imagesetter
4. Disconnect the Loading Encoder Cable
5. Remove the solenoid assembly by releasing the two cross screws that attached it to the frame.
6. Release the two screws on each side that attached the fork to the Rocker.
7. Release the 1/4" screws from each side. Those screws are the Rocker Shaft.
8. Move the rocker to the release slot and remove the Rocker from the Loading drawer.
9. If the two springs are released remove the forks. It is possible to remove the rocker and to leave the springs with the forks with the force.

Assembly

1. Insert the rocker back to its place. Insert the two "shaft screws".

Connecting the right fork

1. Release the top cross screw of the spring holder. This will stop the spring holder and will not allow it to rotate.
2. Make sure that the rocker is in the lower position and set the right spring to the right fork. Insert the two screws when the spring is inside the fork.
3. Make sure that the fork will not touch the slot while the rocker is moving between the upper position and the lower one.

Connecting the left fork

1. Release the top cross screw of the spring holder. This will stop the spring holder and will not allow it to rotate.
2. Make sure that the rocker is in the upper position and set the left spring to the left fork. Insert the two screws when the spring is inside the fork.
3. Make sure that the fork will not touch the slot while the rocker is moving between the upper position and the lower one.
4. Make sure that the rocker is forced inside in the lower position and it is open in the upper position.
5. Connect the loading encoder cable.

Inner Loading Roller (Driving Roller) - Disassembly

To perform assembly - Follow the Disassembly Procedure in reverse.

Disassembly Procedure

1. Unload the film from the Imagesetter.
2. Remove the Loading Cassette.
3. Power off the imagesetter.
4. Remove the Loading Motor:

1. Disconnect the motor cable.
2. Release the two screws that attached the motor bracket to the right flange.
3. Remove the motor. Make sure that the inner part of the coupling motor will not fall down.
4. Disconnect the part of the coupling from the roller edge.

5. Remove the center support by releasing the two screws that attached it to the V block.
6. Remove the "film guide, loading inner" by releasing two screws from each side. Regular screws on the right side and shoulder screws on the left side.
7. Remove the film in detector by releasing the one screw that holds the detector on the left side.
8. Release the two cross screws that hold the solenoid assembly.
9. Remove the two 4/40 screws from the roller bushing (on the left side).
10. Remove the spring washer and the washer from the roller.
11. Gently remove the roller to the left side.

Mouth Assembly

Sometimes the Mouth assembly (between the unloading path & the accumulative cassette) will not sit properly after disassembly and re-assembly.

It is important to pay special attention to the following during mouth assembly:

During the installation of the mouth make sure that the top corner of the mouth will not touch the lower door shaft holder. The mouth must fit and rest on the flange on both sides.

In the future a change on new parts will be done and it will be easier to install the mouth.