HC5000 Tech

DANKA AUSTRALIA PTY. LTD.
HC5000
TECHNICAL MANUAL
REVISION 3.0
DECEMBER 2005
Copyright: 2005 Riso Kagaku Corporation

All Rights Reserved. This Technical Manual was prepared
and written for the exclusive use of RISO International Group
Certified Dealers. Reproduction and/or transmittal of this
material in any form or by any means, including photocopying
or recording of the information is strictly prohibited without the
consent of a member of RISO International Group.
RISO INTERNATIONAL GROUP
RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)

RISO, INC. (U.S.A.) RISO FRANCE (FRANCE)
RISO EUROPE LIMITED (U.K.) RISO IBERICA (SPAIN)
RISO HONG KONG LIMITED (HONG KONG) RISO CANADA (CANADA)
RISO U.K. (U.K.) ZHUHAI RISO TECHNOLOGY (CHINA)
RISO THAILAND LIMITED (THAILAND) RISO AFRICA (SOUTH AFRICA)
RISO KOREA LIMITED (KOREA) RISOGRAPH ITALIA (ITALY)
INDEX
Maintenance Notes
1.Precautions.....................................................................................................4
1-1.General precautions ...........................................................................4
1-2.Special precautions for color inkjet printers .......................................4
1-3.Other precautions for inspection and maintenance............................5
1-4.Sensors ..............................................................................................6
2.Tools ...............................................................................................................7
2-1.List of general tools ............................................................................7
2-2.List of special tools for servicing HC5000 ..........................................8
2-3.Periodical Maintenance ....................................................................11
3.Printer setup procedure ................................................................................12
3-1.Confirmations to be performed during printer setup.........................12
4.Other precautions .........................................................................................35
4-1.Precautions for machine setup.........................................................35
4-2.Precautions for use ..........................................................................35
4-3.Printing precautions .........................................................................36
Removal of Covers
Disassembly 2
1.Removal of covers ..........................................................................................2
Device overview
1.Main features of HC5000................................................................................2
2.Main specifications of HC5000 .......................................................................3
3.Overview of Mechanisms................................................................................4
3-1.Structural blocks.................................................................................4
3-2.Overview of paper transport ...............................................................5
3-3.Ink flow passages...............................................................................7
First paper feed section

Mechanisms 2
1.Standard paper feed tray mechanism.............................................................2
1-1.Basic mechanism ...............................................................................2
1-2.Paper size detection mechanism .......................................................3
2.Standard paper feed tray elevating mechanism .............................................4
2-1.Basic mechanism ...............................................................................4
2-2.Feed tray button .................................................................................4
2-3.Standard paper feed tray operation safety mechanism ..................... 6
3.Remaining paper volume detection mechanism ............................................ 7
4.First paper feed mechanism........................................................................... 8
4-1.Paper transport mechanism............................................................... 8
4-2.Paper stripper mechanism ............................................................... 10
4-3.Paper feed pressure adjustment mechanism .................................. 10
Disassembly 11
1.Standard paper feed tray unit....................................................................... 11
1-1.Removal of standard paper feed tray unit........................................ 11
1-2.Removal of paper width VR, paper detection sensor, and paper size
detection sensor............................................................................... 13
2.Pickup roller shaft......................................................................................... 14
2-1.Removal of pickup roller shaft (pickup roller, scraper)..................... 14
2-2.Removal of first paper feed stay assembly ...................................... 15
2-3.Removal of paper feed clutch and paper feed shaft ........................ 16
3.Elevator mechanism & bottom guide plate................................................... 17
3-1.Removal of elevator motor............................................................... 17
3-2.Removal of bottom guide plate ........................................................ 19
3-3.Removal of standard paper feed tray lower limit switch................... 20
Adjustment 21
1.Adjustment of the upper limit sensor position............................................... 21
2.Adjustment of stripper pressure ................................................................... 22
3.Paper width VR correction............................................................................ 22
4.Other adjustments ........................................................................................ 23
4-1.Standard paper feed tray upper limit position .................................. 23
4-2.Standard paper feed tray postfeed .................................................. 23
4-3.Paper feed start from standard paper feed tray ............................... 23
4-4.Assist for standard paper feed tray .................................................. 23
4-5.Multiple feed detection for standard paper feed tray........................ 23
4-6.Gap between the papers.................................................................. 23
Multi-tray paper feed section

Mechanisms 2
1.Machine configuration .................................................................................... 2
1-1.Basic structure ................................................................................... 2
1-2.Paper transport path .......................................................................... 3
2.Paper transport section in the MTPF Unit ...................................................... 4
2-1.Paper feed tray .................................................................................. 4
2-2.Feed tray elevating mechanism ......................................................... 4
2-3.Paper transport mechanism............................................................... 6
2-4.Vertical transfer unit ........................................................................... 8
Disassembly 10
1.Paper feed trays ........................................................................................... 10
1-1.Removal of paper feed trays ............................................................10
1-2.Removal of paper width VR (potentiometer) ....................................11
2.Paper transport unit in the MTPF Unit. .........................................................12
2-1.Removal of paper transport unit.......................................................12
3.Vertical transfer unit......................................................................................14
3-1.Removal of vertical transfer unit.......................................................14
4.Disassembly of other parts ...........................................................................18
Adjustment 19
1.Adjustment of upper limit sensor position .....................................................19
2.Stripper adjustment.......................................................................................20
3.Power width VR correction ...........................................................................21
4.Multiple feed sensor (feed sensor 3) adjustment..........................................21
5.Other adjustments ........................................................................................21
5-1.Amount of postfeed ..........................................................................21
5-2.Assist................................................................................................21
5-3.Double-feed detection timing. ..........................................................21
Second paper feed section

Mechanisms 2
1.Mechanism of the second paper feed section ................................................2
1-1.Paper transport path ..........................................................................2
1-2.Drive system for paper transport ......................................................11
Disassembly 13
1.Registration roller upper ...............................................................................13
2.Registration roller lower ................................................................................16
3.Side registration unit .....................................................................................20
4.Transfer unit..................................................................................................23
5.Transfer belt..................................................................................................26
6.Belt encoder..................................................................................................28
7.Transfer belt motor .......................................................................................29
8.Suction fan....................................................................................................30
9.Cleaning roller...............................................................................................31
10.Exit unit .......................................................................................................32
10-1.Exit motor unit ................................................................................33
10-2.Wing motor.....................................................................................33
11.Sponge roller ..............................................................................................34
12.Flipper unit ..................................................................................................36
13.Flipper roller upper / Flipper roller lower .....................................................38
14.Duplex entrance roller.................................................................................40
15.Duplex unit..................................................................................................42
16.Duplex belt upper........................................................................................43
17.Duplex belt lower ........................................................................................45
18.Switchback unit upper.................................................................................46
19.Switchback unit lower .................................................................................47
20.Switchback drive roller ............................................................................... 49
21.Switchback unit .......................................................................................... 50
22.Main motor ................................................................................................. 51
23.Registration clutch...................................................................................... 52
24.Paper feed clutch ....................................................................................... 54
25.Duplex clutch unit ....................................................................................... 56
26.Multiple feed sensor (receive) .................................................................... 57
27.Lift gear unit................................................................................................ 60
28.Multiple feed sensor (send) ........................................................................ 63
Adjustment 64
1.Adjusting the skew of the transfer unit belt................................................... 65
2.Adjustment to position the transfer unit parallel to registration rollers.......... 68
3.Transfer belt speed adjustment.................................................................... 72
4.Initial paper feed motor adjustment .............................................................. 73
5.Adjustment of backup roller position ............................................................ 75
6.Adjustment mechanism of registration roller paper guide ............................ 76
7.Adjustment of the Registration roller upper .................................................. 77
8.Adjustment mechanism of registration roller guide ...................................... 78
9.Adjustment of frame distortion compensation .............................................. 79
10.Adjustment of CCD gain on the side registration unit................................. 80
11.Adjustment of the Flipper Gate position ..................................................... 82
Cleaning method 85
1.Removal of paper dust ................................................................................. 85
2.Cleaning the rollers ...................................................................................... 87
Ink supply passages

Mechanisms 2
1.Mechanism of ink supply passages................................................................ 2
1-1.Ink supply passages .......................................................................... 2
1-2.Main parts of the ink feed passages .................................................. 4
1-3.Main parts in the waste ink passage................................................ 15
1-4.Mechanisms common to the ink feed and waste ink passages ....... 21
1-5.Operations of ink supply passages .................................................. 22
Disassembly 25
1.Bottle joint (K, C, M, Y)................................................................................. 25
2.Receiver PCB............................................................................................... 29
3.Ink Reservoir K / C / M / Y............................................................................ 31
4.Overflow tank ............................................................................................... 36
5.Pressure pump unit ...................................................................................... 37
6.Pressure chamber ........................................................................................ 38
7.ID unit / ID solenoid valve............................................................................. 39
7-1.ID unit............................................................................................... 39
7-2. <Removing ID solenoid valve > ...................................................... 42
8.Print head ..................................................................................................... 43
9.Head drive PCB ............................................................................................47
10.Cleaning unit...............................................................................................48
11.Suction head...............................................................................................51
12.Cap .............................................................................................................52
13.Suction chamber.........................................................................................53
14.Ink catch pan ..............................................................................................55
15.Waste ink tank ............................................................................................56
16.Waste ink tank holder .................................................................................57
17.Suction pump unit, pump filter, pump sponge ............................................58
Adjustment 61
1.Adjustment after print head replacement......................................................61
1-1.Parameter setting .............................................................................61
1-2.Preparation for the image adjustment ..............................................62
1-3. Connection of USB cable from the machine to Laptop PC. ............62
1-4.Installation method of the USB driver...............................................63
1-5.Set up method of auto image adjustment software ..........................63
1-6.Set up method of manual image adjustment software .....................63
1-7.Image adjustment procedure ...........................................................63
1-8.Warm-up operation for the transfer belt ...........................................64
1-9.Setting adjustment patterns on the flatbed scanner .........................64
1-10.Placing the A4 size Matte Paper correctly on the feed tray ...........65
1-11.Execution of Auto Image Adjustment .............................................66
1-12.Execution of Manual Image Adjustment.........................................74
2.Adjustments on the Cleaning Unit. ...............................................................80
2-1.Cleaning start position......................................................................80
2-2.Cleaning position..............................................................................81
2-3.Cleaning finish position ....................................................................82
Troubleshooting
Troubleshooting for printing problems 2
1.Causes of main printing problems and corrective measures..........................2
1-1.Procedure for responding to printing problems ..................................2
2.Explanation of automatic image adjustment and adjusted image quality .......5
2-1.Overview of automatic image adjustment ..........................................5
2-2.Overview of test patterns for image adjustment .................................5
2-3.Parameters and image quality ...........................................................5
2-4.Image defects caused by erroneous image adjustment performed by
service personnel ...............................................................................6
2-5.Effects of parameters and image characteristics ...............................9
Paper receiving section

Mechanisms 2
1.Basic mechanism ........................................................................................... 2
1-1.Overview of mechanism..................................................................... 2
2. Fence sliding mechanism.............................................................................. 4
2-1.Fence sliding mechanism .................................................................. 4
2-2.Sliding operations at the beginning of the print operation.................. 6
2-3.Other .................................................................................................. 6
Disassembly 7
1.Paper receiving tray ....................................................................................... 7
1-1.Removing the paper receiving tray < disassembly > ......................... 7
1-2.Removal of covers ............................................................................. 8
2.Side fence belt section ................................................................................... 9
2-1.Removing the side fence belts........................................................... 9
2-2.Removing the side fence pulse motor................................................ 9
3.Removing the end fence pulse motor and sensors ...................................... 10
Adjustment 11
Controller & power supply unit

Mechanisms 2
1.Controller (PS7R) ........................................................................................... 2
2.Removing the controller (PS7R)..................................................................... 4
3.Disassembly and reassembly of controller (PS7R) ........................................ 5
4.Power supply.................................................................................................. 6
Test mode
Test mode 2
1.Operation method........................................................................................... 2
1-1.Startup and shutdown for Test mode................................................. 2
1-2.Operations in Test mode.................................................................... 2
2.List of menu items .......................................................................................... 3
2-1.Menu items in Normal SE mode ........................................................ 3
Panel messages
Overview of panel messages 2
1.Overview of panel........................................................................................... 2
2.Basic structure of panel.................................................................................. 2
2-1.Power key .......................................................................................... 2
2-2.Print mode key ................................................................................... 3
3.Error indication by LEDs................................................................................. 4
3-1.Outline diagram.................................................................................. 4
3-2.Consumables information .................................................................. 4
3-3.Error types ......................................................................................... 4
4.Panel messages .............................................................................................5
4-1.Overview of messages .......................................................................5
5.Types of errors................................................................................................6
5-1.Error type ...........................................................................................6
5-2.Explanation of panel messages .........................................................9
Electrical Parts List

1.Assembly sections ..........................................................................................2
1-1.Covers ................................................................................................2
1-2.Standard paper feed tray section .......................................................3
1-3.Registration roller section...................................................................4
1-4.Side registration unit section ..............................................................5
1-5.Flipper section....................................................................................6
1-6.Duplex unit inlet section .....................................................................7
1-7.Exit unit section ..................................................................................8
1-8.Duplex unit section.............................................................................9
1-9.Transfer unit section.........................................................................10
1-10.Cleaning unit section ......................................................................11
1-11.Ink cartridge holder section ............................................................12
1-12.Ink reservoir section .......................................................................13
1-13.Print head section ..........................................................................14
1-14.Power supply unit & Suction chamber section ...............................15
1-15.PCBs ..............................................................................................16
1-16.Drive section ..................................................................................17
PCBs and Schematic diagrams

1.Role of PCB ....................................................................................................2
2.Power Supply Unit ..........................................................................................4
3.Notes at the time of ORIP PCB exchange......................................................5
4.Downloading/Upgrading the machine program firmware................................7
5.Exchange of ORMC (mechanical control) PCB ..............................................8
6.Schematic .....................................................................................................10
Maintenance Notes
CHAPTER 1: Maintenance Notes
CONTENTS
1-1
HC50 00 200 5/1 2 (Rev 3.0 )
CAUTION
[ Handling of Lithium Battery ]
-Never fail to follow the following instructions when you discard the used lithium
battery.
1. Never let the battery short-circuited.

If the (+) and (-) terminals contact each other or metal materials, the battery
will be short-circuited. If the batteries are collected and stored inorderly or
one upon another, the above-mentioned case will occur.
- DANGER -
If the battery is short-circuited, it will heat up and may in some cases
explode into fire.
2. Never heat up the battery.
- DANGER -
If you heat the battery up to more than 100 degrees Celsius or put it into the
fire, it may burn dangerously or explode.
3. Never disassemble the battery or press it into deformation.
- DANGER -
If you disassemble the battery, the gas pouring out of the inside may hurt
your throat or the negative lithium may heat up into fire.
If the battery is pressed into deformation, the liquid inside may leak out of
the sealed part or the battery may be short-circuited inside an explode.
4. Never fail to keep the battery out of reach of children.
If you put the battery within reach of children, they may swallow it down.
Should they swallow the battery, immediately consult the doctor.
[ Replacement of the Lithium Battery ]
1) The lithium battery must be replaced by a trained and authorized service

technician.
2) The battery must be replaced only with the same or equivalent type recom-
mended by the manufacturer.
3) Discard used batteries according to the manufacturer instructions.
1-2 RISO KAGAKU CORPORATION -Technical Training Center-

Maintenance Notes
!! WARNING !!
Important Safety Precautions
(1) Always disconnect electrical supply before placing hands in the machine.
1) To avoid injuries:
Be sure to disconnect the electrical power before disassembling, assembling,
or when making adjustments on the machine.
2) Protection of the machine:

Make sure to turn OFF the power to the machine before plugging or unplug-
ging the electrical connectors, or when connecting a Meter.
(2) WARNING:
The back light tube of LCD of the Control Panel on this Model contains mercury
which must be recycled or disposed of as hazardous waste.
(3) Always connect electrical connectors firmly.
1) To avoid electrical failure:

The connectors must be connected firmly together and onto the PCBs.
Press on the ends of the connectors and then on the middle to ensure a firm
fit.
2) Protection of the electrical components:

The electrical components may be damaged due to short circuits caused by a
loose connector.
Wire harness connector
FIRST
Press the ends.
THEN Press the center, firmly.
1-3
HC50 00 200 5/1 2 (Rev 3.0 )
1.Precautions
1-1.Gen eral precautions

* U n p l u g t h e p o w e r c o r d f r o m t h e A C o u t l e t b e f o r e p e r f o rm i n g m a i n t e n a n c e .
* B e c a r e f u l t o a v o i d g e t t i n g n e c k t i e s , c l ot h i ng , or l on g h a i r t a n gl e d i n
m ov i n g p a rt s .
* I f y o u m u s t p e r f o rm w o r k w h i l e t h e m a c h i n e p o w e r i s o n , e x e r c i s e t he
utmost caution.
* Never perform maintenance while the machine is operating.
* W o r k c a r e f u l l y t o a v o i d i n j u r i n g y o u rs e l f o n t h e s h a r p e d g e s o f m e t a l s h e e t s
or springs.
1-2.Speci al p reca ution s fo r c olor ink jet pri nters

* Maintain the device to keep it free of dust (including paper dust).
• Dust and paper dust adhering to the nozzles of the print heads may result in a misfire.
• Clean internal paper paths with a vacuum cleaner to remove dust (including paper dust) at peri-
odic intervals - for example, when replacing waste ink tanks (periodic inspections). Clean more
or less frequently, depending on your specific operating conditions. The amount of paper dust
that accumulates in the machine will depend on the type of paper used.
• Never use an air duster, since doing so will raise paper dust and causes misfires.
* I n k s t o ra g e
• Store ink cartridges in the specified conditions. Follow the [first in, first out] principle when
removing ink cartridges from storage, and use ink promptly.
• Do not store ink cartridges in environments that may degrade the ink. Degraded ink is more
likely to cause nozzle misfires and other problems.
* Precautions for use of inks
• Do not shake the ink bottles before using.
Shaking the bottle will generate air bubbles and mix sediment into the ink solution, making noz-
zle misfires more likely.
• Do not refill with ink.
• Check ink left unused for extended periods after ink cartridges are unsealed to make sure it
remains usable.
Ink left in ink cartridges for extended periods after the cartridges are unsealed will oxidize and
degrade. Try to use up ink as quickly as possible after ink cartridges are unsealed.
Using degraded ink may result in problems that require the replacement of the print heads or
other ink-handling parts (misfiring nozzles).
* P r e c a u t i o n s f o r a n t i c i p a t e d p e r i o d s o f e x t e n d e d d is u s e
• Ink in the internal ink passages may degrade or dry out over time, resulting in nozzle misfires
and other problems. In the worst cases, misfiring nozzles will require replacing the print heads.
• To avoid these problems, we recommend operating the printer now and then.
* P r e c a u t i o n s f o r u s e o f t h e p ri n t e r a f t e r l o n g s t o ra ge
• If print head cleaning is not performed before use, misfiring nozzles or other printing problems
may occur.
Start by checking for any misfiring nozzles.
• If the nozzles are misfiring, perform head cleaning.
In some cases, the head cleaning procedure will need to be repeated several times to clear the
print head nozzles.

Maintenance Notes
• If the nozzle condition does not improve after the nozzles are checked for misfiring and strong
cleaning (conducted for each color) is repeated several times, the print heads may need to be
replaced.
* Differences between display and print colors
• The colors on prints may differ slightly from the colors seen on your display device.
• The difference in the colors may be attributable to various factors, including differences between
RGB and CMYK color systems, the RIP color system, display device settings, etc.
* Never touch the surfaces of the print head nozzles.
• Scratching the print head nozzle surface or dust adhering to the print head nozzle surface may
cause printing problems. Never wipe the print head nozzle surface.
• In the worst cases (misfiring nozzles), such problems may require replacement of the print
heads. To prevent problems, avoid touching print head nozzle surfaces during machine mainte-
nance. Be careful to avoid scratching print head nozzle surfaces with tools or parts when work-
ing near the print heads.
* Protect the print heads from any physical shock.
• The print heads are extremely fragile. Handle them carefully, and avoid dropping or striking
them.
* Selection of paper type
• Use only the specified paper type. Using the wrong paper may result in poor adhesion of ink to
the paper.
• If you choose to use a paper product not specifically recommended by the manufacturer, first
perform a printing test. Papers producing paper dust will cause misfires.
• Ink that fails to adhere to the paper may be left on the transport roller or transfer belt, smudging
subsequent prints.
• Internal parts contaminated by ink may require more frequent maintenance. To avoid these
problems, select your paper carefully.
* M a i n t e n a n c e o f p ro p e r o p e r a t i n g c o n d i t i o n s
• Ink viscosity affects the ink ejecting performance of inkjet printers.
• Ink viscosity increases with lower temperatures, making ejection problems like nozzle misfires
more likely. Use the printer only under the specified operating conditions.
* Cleaning wipe
• To wipe off ink from the printer, use the Kimtech or Kimwipe products manufactured by CRECIA
Corp. or similar dust- and fiber-free materials. Never use ordinary tissue paper.
• Fibers and paper dust from cleaning materials may cause nozzle misfires and other problems.
• Never wipe the print head (the head surface). Let the machine clean the head by itself.
1-3. Other precautions for in specti on a nd mai nten ance

Precautions for inspections
• If a defect or abnormality is found during inspections, correct the problem and replace parts, if
necessary.
P re c a u t i o n s f o r p a r t s r e m o v a l
• When ascertaining the location of a problem, also determine the cause of the problem. After
determining whether it is necessary to remove parts or disassemble the machine, perform the
required repairs according to the procedures given in the technical manual.
• Watch for ink leaks when disassembling ink-handling components.
• When disassembling a component consisting of many parts, similar parts or symmetrical right
and left parts, organize the removed parts to ensure proper reassembly.
1) Set aside and arrange removed parts.
2) Clearly identify which parts are to be replaced and which parts are to be reused.
3) When replacing screws or other fasteners, use only parts of the specified size.
1-5
HC50 00 200 5/1 2 (Rev 3.0 )
Precautions for reinstallation and reassembly
• To reassemble or reinstall parts, follow the disassem-
bly or removal sequence in reverse, unless otherwise half pierced
specified.
• If parts have protrusions and indentations for position-
ing (half pierced), align them carefully to ensure
proper installation.
Precautions for electrical work
• If bundled wires have come loose, use a cable tie or
band to hold them together after finishing the work.
• When installing parts, be careful to avoid pinching or
damaging electrical wires.
• Replace blown or defective fuses with fuses of the
specified capacity rating.
In addition to equipment damage, using a fuse with a rating above the specified value may result
in fire.
Others.
• In making the adjustment by SE mode, No.8.5.6.1 must be activated to save the changed data
onto both the NVRAM on the ORIP PCB and FlashMemory. Otherwise the change is down-
loaded onto the NVRAM only with no backup.
• If this process is omitted, restoring the data will take time when a parameter error occurs on the
NVRAM.
• If the updated information is always stored in the FlashMemory, No.8.5.6.2 by the SE-mode eas-
ily restores the data back onto the NVRAM.
1-4.Senso rs
• Be sure to turn off power before disconnecting or connecting sensors.
Ph oto sen so r ty pes
• In general, photo sensors can be divided into four types: the interrupt type (U-shaped), the actu-
ator type, the reflection type, and the transmission type.
interrupt type (U-shaped) actuator type
send
send
receive
receive
reflection type
transmission type
send
send
receive
receive
M a g ne t i c s e n s o r t y p e s
• Some magnetic sensors use Hall ICs, while others use magnetic reed switches.

Maintenance Notes
Switch types
• Microswitches use either N.O. (Normally
Open) contact or N.C. (Normally Closed)
contact.
• The N.O. contact closes when the switch N.C. N.C.
actuator is pressed. N.O. N.O.
• The N.C. contact opens when the switch
COM COM
actuator is pressed.
2 . Too l s
• Using tools other than those specified may result in damage to screws or other parts, or result in
personal injury. Be sure to have all the necessary tools on hand before beginning work.
2-1. List of general tools
Type Size Shaft length, etc.

Phillips screwdriver No. 2 250 mm
No. 2 100 to 150 mm
No. 2 Stubby type
No. 1 75 to 100 mm
Flathead screwdriver 6 mm 100 to 150 mm
3 mm 100 to 150 mm
1.8 mm Precision type
Box driver 8 mm 100 to 150 mm
7 mm 100 to 150 mm
5.5 mm 100 to 159 mm
Spanner 5 mm, 5.5 mm, 7 mm, 8 mm, 13 mm, adjustable
Allen wrench 6.0mm, 5.0 mm, 4.0 mm, 3.0 mm, 2.5 mm, 2.0 mm, 1.5 mm
Steel measure 150 mm, 300 mm
Long-nose pliers
Pliers
Snap-ring pliers
Nipper
Penlight
Tester
Soldering iron 20 to 30 W
File Flat, rounded
1-7
HC50 00 200 5/1 2 (Rev 3.0 )
2-2.L ist of s pecial too ls for serv icing HC5000
HEAD ANGLE JIG

For adjustment of print head position after replacement.
5.5-mm box driver with adjustment scale (8 equally
spaced marks around the periphery).
Transfer unit support jig

For removal of belt-drive transport unit.
Provided inside the machine.
Transfer belt stand jig

Jig for holding the Transfer belt unit vertically for easy
removal of the transfer belt from the unit by a single indi-
vidual. Transfer belt replacement by a single individual is
not recommended without this jig.
Interlock switch jig

Jig for temporarily deactivating the interlock switch so
that the right/left front door remain open during operation
checks.
• Jig 1 : Top photo (2 pcs) - right hand door removed.
• Jig 2 : Center photo (1 pc) - left hand door removed.
• Jig 3 & 4 : Bottom photo for - inner cover removed.
Printer unit lifting jig

Used to raise and move the machine for equipment
setup.

Maintenance Notes
Image adjustment utility software:

Software [ADJUST]: For auto-adjustment using A4 scanner.
Software [or Tool Box]: For manual adjustment.
Software [OR_PRINT]: Print utility software.
Notebook PC (commercially available)

Used to run image adjustment utility software and perform
image adjustment and other tasks.
The following are the minimum hardware requirements:
OS: Windows 2000 or XP
CPU: OS-compatible
HDD: Minimum free space of 500 MB
USB 2.0 (2 or more ports)
Flatbed scanner (commercially available)

Used for image adjustment after print head replacement.
CANON CanoScan LiDE 35, 40, or 50. [A4 size scanner]
EPSON GT-7400U or ES-7000H. [A3 size scanner]
REFERENCE CHART
Reference chart used for scanner calibration during
image adjustment.
[When using A4 scanner, the chart must be cut to the A4-
size line before use if not precut to that size when sup-
plied.]
USB 2.0 cables: 2 types of cables (commercially available)

One normal type USB 2.0 cable and one USB 2.0 extension
cable.
Used for image adjustment
• Printer unit - PC [extension USB 2.0 cable]
• PC - Scanner [normal USB 2.0 cable]
1-9
HC50 00 200 5/1 2 (Rev 3.0 )
Cleaning wipes (commercially available)

For cleaning inside the device.
Kimtech, Kimwipe (manufactured by CRECIA Corp.), or
similar product. Use a wiper that leaves no fiber or paper
residue. Never use ordinary tissue paper.
Gloves (commercially available)

To be worn when replacing ink-handling parts.
Use powder-free gloves, such as the Cleanoir nitrile
gloves manufactured by [As One Corporation]. Do not
use gloves coated internally with lubricating powder,
since powder from the gloves may enter ink passages
and cause nozzle misfires. Gloves of any type are suit-
able for handling waste liquid. Use gloves to protect
hands from ink and waste liquid.
Vacuum cleaner (commercially available)

Used to remove paper dust from inside the machine.
Binder clip (commercially available)

Used to clamp tubes containing ink to prevent ink from
leaking out when the tubes are disconnected and
removed. [Not recommended if the clips tend to deform
the ink tubes.]
IPA (isopropyl alcohol) or equivalent

Used for cleaning rollers.
A4-size coated paper

Used in image adjustment.
1 - 10 RISO KAGAKU CORPORATION -Technical Training Center-

Maintenance Notes
Loupe (magnifier)
For inspection of printing problems, such as color shifts.
Torque driver
Used to tighten replaced print heads to the specified
torque of 9.0 kfg-cm.
Syringe of about 20 ml in size (commercially available)

For removing ink from the Overflow Tank or from the ID
Unit.
(New unused syringe should be used when removing ink
from the ID Unit.)
Air Filter
Manufacturer: SARTORIUS
Type: Minisart 17594-K 5.0 micrometer
Needed when sending air to the ID Unit using the
Syringe to remove ink from the ID Unit.
(This is to prevent dust from getting into the ID Unit.)
2-3. Period ical Ma inten ance

Parts in which without a periodical maintenance cannot keep the good operation of the machine.
Part Name Maintenance Interval Reference

Pump sponge in Suction Unit Replacement Approx. 300,000
Pump filter in Suction Unit printing.
Waste ink tank
Cleaning roller
Transfer unit (Belt & Plate) Cleaning Approx. 300,000 Chapter 6
printing.
Switchback roller Cleaning Approx. 300,000 Chapter 6
printing.
CCD on Side registration unit Cleaning Approx. 300,000 Chapter 6
printing.
Top edge sensor Cleaning Approx. 300,000 Chapter 6
printing.
1 - 11
HC50 00 200 5/1 2 (Rev 3.0 )
3.Printer setup procedure
3-1.Confirmatio ns to be pe rformed du rin g printer setup

• After opening the packages, install and connect the HC5000 main unit, HC control PCB, HC
multi-tray paper feed base, RS7R (controller), and ink cartridges.
• The device will not function correctly if you install an incorrect (incompatible) component in the
HC5000 main unit (MC board), HC control PCB, or ink cartridges, due to a delivery error or other
reason.
• If you discover an incompatibility among components, return the incorrect component for an
exchange. A [Temporary Registration Period] is provided to allow temporary use of the printer
during this time.
N ot e s re g a r d i n g t e m p o ra ry re g i s t r a t i o n s t a t u s
• After the package is opened and the machine set up, [Temporary Registration Status] becomes
effective when the machine is turned on for the first time. After seven days, the status changes
automatically to [Official Registration Status].
• When in temporary registration status, the [Maintenance Call] LED remains lit. Since the
machine can still operate in this condition, exercise all of the precautions normally required.
• Therefore, it is necessary to check all the components and consumables for the compatibility
during the installation, or on the 8th day from the installation the error will show.
• During the tentative-registration period, No.5.13.1 by the SE mode will turn off the Maintenance
call LED , but it only erases the LED and the tentative-registration still remains.
• SE mode No.5.13.2 cancels No.5.13.1 of the above and lights the Maintenance call LED again.

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
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HC50 00 200 5/1 2 (Rev 3.0 )

Maintenance Notes
4.Other precautions
4-1. Precautions for mach ine setup

F o r d e t a i l e d i n f o r m a t i o n , r e f e r t o t h e U s e r s M a n ua l f o r t h e H C 5 0 0 0 S e r i e s .
• Discuss with the user to determine where the product is to be installed upon delivery.
• To minimize the possibility of malfunctions, equipment problems, and accidents, do not install in
any of the following locations:
1) Places exposed to direct sunlight, or bright locations by windows.
(If the machine must be installed by a window, install a curtain or shade on the window.)
2) Places subject to significant temperature fluctuations.
3) Places subject to extremes of temperatures or humidity.
•Appropriate temperature range: 15 to 30 degrees Celsius
•Appropriate humidity range: 40 to 70% (no condensation permitted)
4) Places close to flames or heat sources, close to cold air sources such as air conditioners,
or close to hot air sources such as heaters or direct radiation heat sources.
5) Places without adequate ventilation.
6) Places that are excessively dusty.
7) Places subject to vibrations.
8) Places with uneven or tilting floors.
(Requirements for floor levelness: Max. 10 mm vertical deviation front to back or left to
right)
C o n ne c t i o n o f p o w e r s u p p l y
• When unplugging the power cord, grasp the cord by the plug. Never pull on the cord itself. Pull-
ing on the cord directly may damage the cord and lead to fire or electric shock. Be sure to hold
the plug when unplugging the power cord.
• Use an exclusive AC outlet. Do not share the AC outlet with other electrical devices.
• When using an extension cord, limit the cord length to 5 m.
• Avoid damaging the power cord. Do not attempt to modify the power cord. Avoid placing heavy
items on the cord, or bending the cord sharply. Damaged cords may result in fire or electric
shock.
C on ne c t i o n of g ro u n d w i r e
• To prevent a fire or electric shock in the event of electrical leakage, be sure to connect the
ground wire.
• Observe the following when connecting the ground wire:
• Ground terminal of AC outlet
• Copper rod inserted 65 cm or deeper into the ground
• Ground terminal in compliance with grounding standards
• Water supply pipe approved for grounding purpose by the waterworks department
• Do not connect the ground wire to any of the following locations:
• Gas pipes
• Ground wires designated exclusively for telephones
• Lightning conductors
• Water supply pipes or faucets connected to a pipeline consisting even partially of plastic
4 -2 . Precau t i o n s f o r u se
Operations
• Do not turn off the main power or unplug the power cord while the machine is operating.
• Do not open the cover or move the machine while the machine is operating.
• Open or close covers gently.
• Never place heavy items on the machine. Protect it from sudden and powerful shocks or impact.
1 - 35
HC50 00 200 5/1 2 (Rev 3.0 )
• After the main power is turned off, wait at least 10 seconds before turning it back on.
• After an extended period of disuse, perform maintenance (normal cleaning) for the print heads
to guard against degraded or dried ink in the ink passages that could clog the print heads. To
avoid such problems, use the machine at regular intervals.
• To safeguard against equipment malfunctions and poor print quality, avoid touching the print
heads.
• Make sure that the ink cartridges (4 colors) are installed at all times, even if it will not be used for
a certain period of time.
H a n d l i n g a n d s t o ra g e o f i n k c a r t r i d g e s
• Do not shake the ink bottle before use. Shaking the bottle generates air bubbles and can cause
printing problems.
• Do not refill with ink.
• Ink left in the ink cartridges for an extended period after the cartridges are unsealed may
degrade from exposure to air. In turn, using degraded ink may cause problems with print heads
and ink passages.
• The viscosity of the ink directly affects the ink-ejecting performance of inkjet printers. Viscosity
increases with lower temperatures, potentially clogging print heads. Be sure to observe the
specified operating conditions and storage temperatures. Check the manufacturing date of the
ink to ensure that it is fresh and use it as soon as possible.
• The permissible operating temperature range is 15 to 30 degrees Celsius. Using the machine
outside this temperature range may result in printing problems (e.g., reduced volume of ink ejec-
tion).
• Do not dispose of ink from an ink cartridge into municipal sewers.
• Keep the side with the opening face-up during storage.
• Do not allow ink to freeze. Keep ink out of direct sunlight. Store ink cartridges in areas where the
temperature does not drop below 5 or exceed 35 degrees Celsius. Check the manufacturing
date before use, and use ink as soon as possible.
• The ink used in the device is a flammable liquid.
In the event of fire, use a pressurized water and alkali salt mist, foam, powder or carbon dioxide
fire extinguisher.
Paper handling and storage
• Do not use warped paper.
• Printed images will gradually fade (discolor) due to the effects of various elements in the air and
light. To minimize fading and discoloration during storage, allow prints to dry thoroughly, then
laminate, or place in frames under glass.
• If prints are placed in clear folders for storage, use folders made of PET (polyethylene tereph-
thalate).
• Printed images will discolor if prints are subjected to any moisture (e.g., water or perspiration).
Do not store prints in areas where water may splash on them.Do not use oil-base marker pens.
Ink from these pens may blotch.
• Print density 24 hours after output will differ from the print density immediately after output. Keep
in mind that print density decreases over time.
• Do not place prints produced by this machine on top of prints produced by a laser printer or pho-
tocopier.The toner-printed section of the other print may stick to the print surface, or the toner
may transfer to the print surface.
• Store unused paper by covering with the wrapping sheet.
• Do not store paper in areas of high temperatures or humidity. Keep out of direct sunlight. Store
paper on a flat surface. Note that warped paper cannot be used in the machine.
4-3.Printi ng precau tion s

• It is illegal to make duplicates of certain printed materials, even for personal use.
Note that possession of duplicates of certain printed materials constitutes a legal violation.
• Printing of the following printed materials is illegal:

Maintenance Notes
• Bank notes, coins, government securities, government bond certificates, or local bond cer-
tificates (Any copying of such material is illegal, even if the printed matter is clearly marked
as SPECIMEN or similar indication.)
• Bank notes, coins, bond certificates, etc. circulated in foreign countries.
• Unused postal stamps, postcards, etc.
• Government-issued revenue stamps, certificate stamps specified in the Liquor Tax Law,
etc.
• Do not make copies of the following printed materials:
• Privately issued marketable securities (stock certificates, promissory notes, checks, etc.),
commuter passes, commuter tickets, etc. in numbers exceeding the minimum quantities
required for business.
• Government-issued passports and licenses, permits, identification cards, admission tick-
ets, meal tickets, etc. issued by public or private organizations
• Copyrighted materials such as books, sheet music, paintings, block prints, maps, drawings,
photographs, etc.
• Relevant laws
• Counterfeit Currency and Securities Control Law
• Law Concerning Counterfeiting, Alteration, or Forgery of Coins, Paper Currency, Bank
Notes, or Securities Circulated in Foreign Countries
• Law Concerning Forging of Stamps or Other Postal Materials
• Revenue Stamp Counterfeit Control Law
• Law Concerning Regulation of Securities Resembling Paper Currency
1 - 37
HC50 00 200 5/1 2 (Rev 3.0 )

Removal of Covers
CHAPTER 2: Removal of Covers
CONTENTS
2-1
HC50 00 200 5/1 2 (Rev 3.0 )
Disassembly
1.Removal of covers
CAUTION : Be careful not to drop washers when removing the screws.
< Top cover >

1) Remove the four M4x8 screws with washers.
2) Open the Ink cover and remove the two M4x8 screws with washers.
3) Open the front door and loosen a M4x8 IT screw through the hole.
* Loosen the screw approximately two turns.
* Take care not to drop the screw inside the cover.
4) Lift the top cover to remove.
* Take care not to drop the cover, as injury may result.
* When the Top Cover is removed from the machine, the Ink Cartridge Cover must be kept open, or
otherwise the plastic lock-hook on the Ink Cartridge cover will break off.
* While mounting the Top Cover back on the machine, pay caution not to pinch the wire harness on the
left, right and at the bottom.

Removal of Covers

1) Open the ink cover.
2) Remove the two M4x10 tapping screws on each side that are used to mount the opening/
closing mechanisms.
3) Lift the ink cover to remove.
< Rear cover >

1) Remove the five M4x8 screws with washers.
2) Undo the top center hook to the top cover and slide the rear cover toward the back to
remove.
* Pay caution not to pinch the wire harness when mounting the Rear Cover.
2-3
HC50 00 200 5/1 2 (Rev 3.0 )
< MTPF rear cover >
1) Remove the seven M4x8 binding screws.
2) Slide the MTPF rear cover toward the back to remove.
< MTPF right cover >

1) Remove the five M4x8 binding screws.
2) Remove the MTPF right cover.
< MTPF left cover >

1) Open the MTPF left door and remove the door by taking off two screws on the top.
2) Remove the four M4x8 binding screws from the MTPF left cover
3) Remove the MTPF left cover.
MTPF left door

(This door has to be removed first)
MTPF left cover

Removal of Covers
< Right cover / Left cover >
1) Remove the two M4x8 screws with washers.
2) Pull the cover down to remove.
< Fr on t d o o r R / F ro n t d o o r L >
1) Remove the right / left covers.
2) Remove the four M4x8 screws with washers from the hinges.
3) Open and remove the door.
* With the screws removed from the hinges, the cover is held in place only by magnetic catchers. Since
opening the cover will free it from any support, exercise caution while performing the work.
* To operate the machine without the front door R / front door L in place, set the dedicated safety switch
activating jigs at the safety switches (three locations on the inner cover).
* Remove the front door R / front door L. Check to make sure that the duplex unit and vertical transfer
unit are set if duplex print and MTPF paper supply is used. The setting of the two units can be
checked by closing the door (the door will not close if these two units are not correctly set). Hence,
confirmation is not possible without the door.
2-5
HC50 00 200 5/1 2 (Rev 3.0 )
< Inner cover 1 >
1) Open the front door R / front door L.
2) Remove the three M4x8 screws with washers.
< Inner cover 4 >

3) Lift inner cover 4 to remove. (The bottom portion has hooks.).
< Inner cover 3 >

2) Remove the four M4x8 screws with washers.
3) Remove the two connectors for the interlock switches (located inside the cover). Detach
inner cover 3.

Removal of Covers
< Inner cover 2 >
2) Remove the Inner cover 3.
3) Remove the knob and lever.
4) Remove a M4x8 screw with washer. Detach inner cover 2.
• Cautions in installing the inner cover 2 back on the machine.

* In mounting the lever back on the machine, match the D-shaped hole on the lever with the D-shaped
cut on the shaft. If the D-shaped hole is deformed, correct lever position cannot be achieved.
* Set the Lever to the original default position. The center position is the default.
* Pay caution that the wire harness does not come out.
* Pay caution not to pinch the wire harness.
* Depending on how the cover is mounted back on the machine will change the lever position. The
inner cover 2 should be put back by pushing it to the right and to the bottom, as shown on the last
photograph on this page.
*
Watch out for the wire coming out.
Put the cover back in correct position.

(Push to the right and to the bottom.)
2-7
HC50 00 200 5/1 2 (Rev 3.0 )
< MTPF molding >
1) Open the front door R/front door L.
2) Detach inner cover 4.
3) Detach inner cover 1.
5) Remove the MTPF molding.
Pull the moulding out.

Removal of Covers
< Exit unit cover >
1) Remove the paper receiving tray.
3) Lift the exit unit cover to remove. (The bottom portion has hooks.).
< PCB box cover >

1) Remove the rear cover.
2) Loosen the two M3x6 IT screws.
3) Remove the 17 pcs of M3x6 IT screws.
4) Remove the PCB box cover.
These two screws are

to be loosened only.
2-9
HC50 00 200 5/1 2 (Rev 3.0 )
< How to set the PCB box to the service position >
1) Remove the right and left screws. Lift the PCB box.
2) Using the removed screws, hold the PCB box in the raised position (right and left).
REAR LEFT
REAR RIGHT
Remove screw Stay
Remove screw
REAR LEFT
Fix the PCB box in raised position by the screw, both on the left and on the right.
* Loosen a screw and position the stays out of the way to keep from striking your head against them.
* The dust fan rotates when a print operation is made. Be careful not to touch it and avoid clothing from
getting tangled in the rotating fan.
* Return the PCB box back to the normal position from the service position before closing the PCB box
cover with the screws. Otherwise the PCB box twists and the screw holes for the stay will not align.
* After returning the PCB box to its original position, be sure to engage the tube to the retaining hooks
(at 2 locations.)
the retaining hook

Removal of Covers
< Right carriage cover/left carriage cover >
1) Remove the top cover.
2) Remove the control panel together with the bracket.
3) Loosen the four IT screws holding the ink cartridge holder unit in place, and slide the entire
unit toward the left, looking from the operator’s side.
4) (This step is required only when removing the left carriage cover).
5) Open the front door R/front door L.

6) Lift the knob on the switchback unit U, secure in place, then pull out the duplex unit.
7) Unhook the Flat cable of the operation panel out from the two flat cable saddles and lift the
Flat cable to access to the holes for the screw driver to go in.
the Flat cable
2 - 11
HC50 00 200 5/1 2 (Rev 3.0 )
8) Loosen the two M4x8 IT screws at the back on each carriage cover.
Remove the two M4x8 IT screws at the center.
The two screws at the front on each carriage cover need not be removed.
* The screws at the front, which need not be removed contains spacers. If these front screws need to
be removed, make sure not to drop the spacers.
M4x8 IT screws
(loosen)
No need to remove the

screws in the front.
M4x8 IT screws
(remove)
9) Remove each carriage cover through the gap in the frame.
* When removing or reinstalling carriage covers, be careful to avoid catching and pulling the ribbon
cables connected to the print heads.
* The ink cartridges do not need to be removed when moving the ink cartridge holder unit to the service
position. However, if you remove the ink cartridges for any reason, take care to keep foreign particles
off the joint sections on which the ink cartridges mount. (Additionally, keep the joint sections of the ink
cartridges clean.)

Device overview
CHAPTER 3: Device overview
CONTENTS
3-1
HC50 00 200 5/1 2 (Rev 3.0 )
1.Main features of HC5000
(1) High-speed, full-color duplex printing.

• Fast, full-color single-side printing at a rate of 105 sheets per minute.
• High-speed full-color duplex printing at a rate of 37 sheets per minute (4A-R feed, continuous
printing at standard settings).
• Fast, high-volume color printing.
(2) Cost-effective, full-color printing.
(3) The digital print system (i.e., no press plates required) enables print sorting.
• The absence of press plates allows low-cost printing of full-color booklets consisting of many
pages.
• Printing can be executed for a specified number of copies, eliminating the need for collation after
printing and boosting printing efficiency.
• Supports a wide range of printing needs.
(4) Compatible with a wide range of paper widths

• Capable of printing on paper of various sizes, from postcard to oversized A3.
• Allows full-color printing on envelopes for direct mail advertisements or office use.
• Capable of printing on plain paper and high-grade paper.
• Dedicated paper specially designed to produce top-quality printing results is available.
(5) Standard built-in dedicated RIP and Adobe(R) PostScript(R) 3TM

• The main unit has a built-in dedicated RIP (Raster Image Processor).
• A page description language is widely used at design offices. Adobe(R) PostScript(R) 3TM is a
standard feature.
• Capable of outputting document data produced by advanced graphics applications.
(6) Enhanced network print function; multifunction capability with a scanner.

• The machine is designed exclusively for use as a network printer.
• A single master unit can control up to four slave units. Use the cluster function to divide a print-
ing job between the master unit and a selected slave unit for fast, full-color printing at rates of
210 sheets per minute.
• Use with specified scanners also permits copying of paper documents.

Device overview
2.Main specifications of HC5000
Machine Specification:
Refer to the specification chart on the Users Guide for the machine
specifications.
3-3
HC50 00 200 5/1 2 (Rev 3.0 )
3.Overview of Mechanisms
3-1.Structu ral blo cks

• The HC5000 consists of the following six main blocks:
1) First paper feed section:
This section feeds a single sheet of paper from paper stacked in the standard paper
feed tray, sending it to the second paper feed section.
2) Multi-tray paper feed section:
This section feeds a single sheet of paper from the paper stacked in the two front
paper feed trays, sending it to the second paper feed section.
3) Second paper feed section:
This section transports the papers toward the exit tray as printing is done at the print
head section.
In the case of duplex printing, paper is sent to the switchback section for printing on
the other side.
4) Exit section:
This section transfers printed paper onto the paper receiving tray.
5) Ink supply section:
This section feeds ink from the ink cartridges to the print heads for printing.
Waste ink generated during cleaning is collected in the waste ink tank.
6) Controller (PS7R) section:
The controller (PS7R) installed in the multi-tray paper feed section controls operations
such as execution of print jobs, touch panel operations, and scanner operations.
Ink cartridge
Print head
Switchback section
Paper receiving tray
Standard paper feed tray
Paper feed tray (MTPF)
Waste ink tank Controller (PS7R)

Device overview
3 -2 . Over v iew o f p ap er t r an s p o rt
P a p e r t r a n s p o rt
• Paper is supplied from the standard paper feed tray to registration rollers by two rollers: scraper
and pickup roller.
• From paper feed tray 1, paper is sent by the scraper and pickup roller to the registration rollers
via paper feed rollers 3 and 4.
• In the same way, paper is sent from paper feed tray 2 by the scraper and pickup roller to the reg-
istration rollers via paper feed rollers 1, 2, 3, and 4.
• With a suction fan keeping the paper firmly on the transfer belt, the registration rollers transport
the paper under the print heads for printing.
• After one side of paper is printed, the paper transport direction is selected by the flipper unit flip-
per gate. For simplex printing, paper is transported to the exit tray via the sponge roller.
For duplex printing, paper is transported to the switchback unit via the flipper unit and duplex
unit.
• Paper is then reversed by the switchback unit, and the separation claws send the paper to the
registration rollers once again.
Switchback unit
Duplex unit
Flipper unit
Pickup roller Separation claw
Flipper gate
Registration roller
Scraper
Paper receiving tray
Paper feed roller 4

Suction fan
Sponge roller
Paper feed roller 3 Transfer belt
Paper feed roller 2

Paper feed tray 1
Paper feed roller 1
Paper feed tray 2
3-5
HC50 00 200 5/1 2 (Rev 3.0 )
P a p e r t r a n s p o r t s e n s o rs
• The status of paper transported from the paper feed tray is checked by FL feed sensors 1
through 4.
• A multiple feed can result when A3-size paper is fed from paper feed tray 1, with the second
sheet feeding immediately after the first sheet.
To prevent this, paper feed tray 1 is equipped with Multi-tray 1 pickup sensor.
• FL feed sensor 3 detects the paper transport status and senses multiple paper feeds from the
paper feed tray.
• Multiple paper feeds from the standard paper feed tray are detected by the multiple feed sensor.
• The status of the paper transported to the registration rollers is detected by the registration sen-
sor.
• The top edge sensor detects the leading edge of the paper being transported from the registra-
tion rollers and adjust the print start position.
• The CCD detects both side edges of the paper being transported from the registration sensor
and controls the side printing positions.
• If paper is transported with its leading edge lifted, it may collide against the print heads, damag-
ing the nozzle surfaces. To prevent this, the paper lift detection sensor detects the lifting of the
paper.
• The paper ejection sensor detects the status of the paper transported toward the paper receiving
tray.
• The flipper sensor detects the status of the paper transported through the flipper unit.
• The duplex IN and OUT sensors detect the status of the paper transported through the duplex
unit.
• The switchback sensor detects the paper entering or exiting the switchback unit.
Duplex belt IN sensor
Switchback sensor
Duplex belt OUT sensor

Flipper sensor
Registration sensor
Top edge sensor
Paper ejection sensor
Multiple feed sensor CCD
Paper lift detection sensor

FL feed sensor 4
FL feed sensor 3 FL multi-tray 1 pickup sensor
FL feed sensor 2
FL feed sensor 1

Device overview
3-3. Ink flow p assages
O v e rv i e w o f i n k p a s s a g e s
• Ink passages can be categorized into two main types: passages for supplying the ink required
for printing, and a waste ink passage for carrying ink used in print head cleaning.
• Ink from the ink cartridges is held temporarily in the reservoirs and supplied to the print heads
via ID units (distributors).
• The supply of ink is regulated by the opening/closing of solenoid valves installed in the ink pas-
sages, and by the solenoid valves for the air passage on each ink chamber. An air open filter is
installed to prevent paper dust and other particles from entering the ink passages.
• During cleaning, a pressure pump forcibly expels ink from the print heads. The discharged
waste ink is drained into the waste ink tank by the suction pump.
• If ink overflows from the air open filter, ink cartridges, reservoirs, ID units, or print heads for any
reason, it is sent to the overflow tank and waste ink tank via the ink pan and ink draining tubes.
Air open filter

Print head ID unit Ink cartridge
Ink pan
Ink pan
Suction pump Reservoir
Overflow tank
Waste ink tank Pressure pump
3-7
HC50 00 200 5/1 2 (Rev 3.0 )
I n k s up p l y p a s s a g e s
• Each ink flows from the ink cartridge to the reservoir, to the ID unit (distributor), and then to the
print head.
• The tip of each ink cartridge is equipped with a TAG. When an ink cartridge is set in position, the
TAG communicates with the HC unit to determine the suitability of the ink. If the ink is appropri-
ate, the ink fuse solenoid opens the passage to the reservoir.
• The solenoid valve (ink fuse valve) opens or closes to regulate the flow of ink to the reservoir.
• The ID units and reservoirs must contain certain amounts of ink at all times. Ink sensors are
used to detect ink levels.
• Ink is supplied from the reservoirs to the ID units and to the print heads automatically due to dif-
ferences in the heights of liquid heads. Solenoid valves are not used for this ink supply control.
• The ink cartridges are opened to the atmosphere via a filter (to prevent entry of paper dust and
other particles).
• Although the ID units and reservoirs are open to the atmosphere via the overflow tank and filter,
open/close control must be provided in certain cases. Air open valves are provided for this pur-
pose.
• The ID units are not open to the atmosphere under normal conditions. However, they are
open to the atmosphere while ink is being supplied.
• The reservoirs are open to the atmosphere under normal conditions, but close when ink is
supplied to the ID units and during cleaning operations.
• During cleaning operations, air pressure inside each reservoir is increased to expel ink from the
print head.
The pressure chamber stores air compressed by the pressure pump. The pressure valves open
to send compressed air to the reservoirs.
Air open filter

Ink Cartridge
Print head ID unit
Pressure pump
Air open valve
Ink fuse solenoid
Ink sensor
Press chamber
Reservoir
Overflow tank
Pressure valve
Ink fuse valve

Device overview
Waste ink passage
• During cleaning, ink forcibly discharged from the print heads is drawn forward by the suction
nozzles for collection in the waste ink tank via the suction chamber. (The suction pump draws
ink, while the suction chamber separates the liquid and the air.)
• The waste ink sensor detects the level of waste ink in the waste ink tank.
• If ink overflows from an ID unit or reservoir for some reason, it flows to the overflow tank via the
air open valve.
• If the waste ink level in the overflow tank exceeds the preset level, the overflow tank sensor
detects this condition and stops the machine operation. Ink overflowing from the overflow tank
flows into the waste ink tank through the waste ink collecting pipe.
• Ink that overflows through the air open filter and ink flowing out of ink cartridges and print heads
into the ink pan are also collected in the waste ink tank.
Air open filter

Print head Ink Cartridge
ID unit
Suction nozzle
Ink pan
Air open valve

Suction pump Ink pan
Reservoir
Suction chamber
Overflow tank sensor

Waste ink sensor
Overflow tank
Waste ink tank
3-9
HC50 00 200 5/1 2 (Rev 3.0 )

F i r s t pa p e r f e e d s e c t i o n
CHAPTER 4: First paper feed section
CONTENTS
4-1
HC50 00 200 5/1 2 (Rev 3.0 )
Mechanisms
1 . Sta n d a r d pa p e r f e e d t r a y m e c h a n i s m
1-1.Basi c mech anism

• The paper detection sensor (reflection type) detects the presence/absence of paper in the stan-
dard paper feed tray.
• Since the last sheet of paper in the standard paper feed tray tends to cause multiple feeds, a
final-sheet multiple feed prevention rubber is provided.
• In addition to centering the paper on the tray, the paper guides set on either side of the paper
detects the paper size (paper width).
• To adjust paper feed performance to match the paper size, a special mechanism holds the stan-
dard paper feed tray at a tilted angle. When the standard paper feed tray is lifted slightly, it
remains tilted. When lifted again, it returns to the horizontal position.
Paper guide Final sheet multiple feed prevention rubber

Paper size detection sensor
Paper detection sensor
Paper width potentiometer

1-2. Pap er s ize detecti on me chani sm
< Basic information regarding paper size >
• The size of paper loaded in the standard paper feed tray is set manually through the menu
screen. The menus are 4.1.1 for standard feed tray, 4.2.1 for Tray 1, and 4.3.1 for Tray 2.
• The following paper sizes can be set:
1) Auto (Initial factory setting)
* When [Auto] is selected, the paper width potentiometer and paper size detection sensor mounted in
the standard paper feed tray automatically detect the size of the paper in the standard paper feed
tray.
2) Standard paper sizes to be registered manually.
3) Custom user paper sizes (up to 5 sizes can be registered) by menu 5.1
< Auto detection of paper size >
• The paper width potentiometer and paper size detection sensor detect the size of paper loaded
on the paper feed trays.
• The paper width potentiometer measures the paper width (in practice, it measures the width of
the paper guides set on either side of the paper), while the paper size detection sensor detects
paper length (portrait or landscape orientation).
• The detected paper size is categorized as one of the following standard paper sizes in the chart
below:
Detected paper width Paper size detec- Paper size

(mm) tion sensor
302 - 292 Paper detected A3
No detection A4-R
262 - 252 Paper detected B4
No detection B5-R
215 - 205 No detection A4
187 - 177 No detection B5
105 - 95 No detection Post Card
< C u s t o m s i z e p a pe r d e t e c t i o n >
• In the following condition, the paper size cannot be detected. Therefore, the paper size is dis-
played as [CUSTOM].
• <AUTO> is selected while the paper size is out of above chart.
• The paper on the tray does not match with the registered paper size. (The actual paper size
is detected by the paper width potentiometer and paper size sensor.)
• The [CUSTOM] papers are divided into following two categories according to the paper length
detected by the paper size sensor.
• Customs size L : Long paper. Custom size S : Short paper.
• The location of the paper size sensor is at 320mm position on the Standard feed tray, and
316mm position on the Tray 1 and Tray 2.
4-3
HC50 00 200 5/1 2 (Rev 3.0 )
2 . Sta n d a r d pa p e r f e e d t r a y e l e v a t i n g m e c h a n i s m
2-1.Basi c mech anism

• The standard paper feed tray is raised and lowered by the elevator motor.
• The upper limit position (top stop position) of the standard paper feed tray is detected by the
upper limit sensor. The lower limit position (bottom stop position) is detected by the lower limit
sensor.
• If the standard paper feed tray is at the lowered position when printing begins, the standard
paper feed tray is raised to the upper limit position. To ensure accurate positioning during this
operation, the standard paper feed tray is lowered after stopping at the upper limit position, then
raised once again to the upper limit position.
• If the standard paper feed tray runs out of paper (as detected by the paper detection sensor),
printing halts and the standard paper feed tray descends to the lower limit position.
• Since the top sheet of paper on the standard paper feed tray must be kept at the same height,
when the upper limit sensor turns Off as the paper is fed, the standard paper feed tray elevates
until the upper limit sensor activates.
• The detecting conditions of the two Upper limit sensors, A and B, gives three upper limit position
selections.
Which one of the three upper limit position is applied depends on the type of the paper on the
tray.
* Use SE Modes 5.9.1.1 - 5.9.13.1 to set the stop position for each paper type.
* Refer to page 4-11 for further details.
Upper limit position

　　　　上限位置
給紙上限センサＡ To the
下限方向lower position
Upper limit sensors A
Upper limit sensors B
給紙上限センサＢ
High Middle Low

上中　下
2-2.F eed tray button

• Use the feed tray button to raise or lower the standard paper feed tray manually.
• The tray descends for the period the button is pressed.
• When the standard paper feed tray is at the lower limit position, and if paper is present, the LED
for the feed tray button will light. Pressing the feed tray button in this condition will raise the
standard paper feed tray to the upper limit position.

Elevator upper limit sensor B Elevator upper limit sensor A Feed tray button
Pressure adjust lever sensor Detection plate
Elevator lower limit sensor

Elevator motor
4-5
HC50 00 200 5/1 2 (Rev 3.0 )
2-3.Stan dard pap er feed tra y ope ration s afety mecha nism
• Safety switches are installed at two locations to prevent fingers or other body parts from being
caught by the moving standard paper feed tray. When the safety switch is triggered, the stan-
dard paper feed tray Elevator motor halts the operation and a message is displayed.
• Paper feed tray upper safety SW: When the scraper cover is pushed up, the switch is triggered.
• Paper feed tray lower safety SW: When the lower limit frame is pushed up, the switch is trig-
gered.
Paper feed tray upper safety SW
Paper feed cover
Scraper cover
Lower limit frame

Paper feed tray lower safety SW

3 . R e m a i n i n g pa p e r v o l u m e d e t e c t i o n m e c h a n i s m
• The volume of remaining paper in the standard paper feed tray is determined by the conditions
detected by tray volume sensors A and B, and the remaining paper volume is displayed.
• The actual position of the standard paper feed tray at the upper limit position is checked by the
above two sensors, and the remaining paper volume is detected. If the standard paper feed
tray is not at the upper limit position, the [Non-standard Status] indication is displayed.
However, if the paper detection sensor detects [No Paper], the remaining paper volume is deter-
mined to be 0%.
• When the remaining paper volume drops to 30% or less, the LED on the main unit panel will
light. If monitored from a PC, the paper remaining volume is detected in four levels.
Remaining paper volume indication LED for standard paper feed tray
PC Monitoring screen
Level Sensor status Determined

Sensor A Sensor B Remaining
paper volume
Level 0 OFF OFF 100 to 50%
Level 1 ON OFF 50 to 30%
Level 2 ON ON 30 to 10%
Level 3 OFF ON 10% or less
Interrupt type sensor (fixed)

Detection plate (slides up/down)
4-7
HC50 00 200 5/1 2 (Rev 3.0 )
4 . F i r s t pa p e r f e e d m e c h a n i s m
4 -1 .Paper t r an s p o r t mec han i s m

• The first paper feed mechanism supplies the top sheet from paper stacked in the standard paper
feed tray to the second paper feed section using the rotating scraper and pickup roller.
• The scraper and pickup roller are driven by the main motor, whose rotation is controlled by the
On/Off of the Paper feed clutch.
• To prevent the first paper feed section from holding the paper once the paper is supplied to the
second paper feed section, the scraper and pickup roller contain one way cores to let the paper
travel through freely.
Paper feed clutch On/Off timing
• The paper feed clutch activates to rotate the pickup and scraper rollers at a timing determined
by the paper size and simplex/duplex printing selection.
• Since actual paper length is measured by the top edge sensor, the feed timing for the first and
second sheets will differ from the feed timing for the subsequent sheets.
• When the registration sensor located before the registration rollers detects paper, the paper feed
clutch turns off after a preset time and ends the first paper feed operation.
P i c k u p r o l l e r s ha f t r e v e r s e r o t a t i o n p re v e n t i o n m e c h a n i s m
• Paper supplied from the first paper feed section stops after its leading edge is clamped by the
registration rollers (upper and lower) in the second paper feed section, creating a buckle at the
tip of the paper. The reverse rotation prevention mechanism prevents reversal of the pickup
roller shaft from the stiffer papers kicking back after a buckle is made.
• The reverse rotation prevention mechanism consists of a one-way core and paper release lever.
The one-way core permits the pickup roller shaft to rotate only in the paper transport direction.
• When the reverse rotation prevention mechanism is engaged, jammed paper cannot be pulled
toward the standard paper feed tray side. To release jammed paper, the paper release lever
must be pulled toward the rear side to disengage the teeth of the two ratchets.
One way core
Paper release lever
Scraper Pickup roller

Registration sensor
Pickup roller
Top edge sensor
Paper feed clutch
Scraper
Registration roller Upper

Transfer belt
Registration roller Lower
Paper feed clutch
4-9
HC50 00 200 5/1 2 (Rev 3.0 )
4-2.Paper stripper mechanism
• This mechanism is located under the pickup roller. This mechanism allows only one sheet to
feed at a time from the standard paper feed tray by the first paper feed operation.
• Paper transported by the scraper moves between the pickup roller and stripper pad, after which
the rotating pickup roller feeds the paper through the pickup roller and stripper roller. The friction
provided by these parts ensures that only one sheet of paper is fed to the machine.
• The stripper pressure adjust knob allows adjustment of pre-stripper pressure to prevent multiple
feeds and paper feed failures.
Stripper pad Stripper roller
Stripper pressure adjust knob
4-3.Paper feed p ress ure adjus tment mech anism

• The pressure adjust lever allows adjustment of the spring pressure applied to the paper by the
scraper to two levels, High (thick paper) or Low (standard) selection.
• The lever position is detected by the paper feed pressure sensor.
Pressure adjust lever
Paper feed pressure sensor Pressure adjust lever spring

Disassembly
1 . Sta n d a r d pa p e r f e e d t r a y u n i t
1-1. Rem oval o f standard p aper fee d tray u nit


(1) Lower the standard paper feed tray to the lower limit position and turn off the main power.
(2) Remove the top cover and remove the rear cover.
(3) Raise the PCB box and keep at the raised position.
< Removal >
(1) Remove the press chamber. (two M3x6 IT screws)
(2) Cut the band binding the wires from the standard paper feed tray and disconnect the two relay
connectors and the ground wire (attached to the relay PCB on the paper feed side).
Relay connector
Ground wire
Fastened to PCB
Press chamber
4 - 11
HC50 00 200 5/1 2 (Rev 3.0 )
(3) Remove the damper covers (two M4x8 screws with washers) from the right and left sides of
the standard paper feed tray, damper R (front side, white) (two M3x6 IT screws), and damper
L (rear side, black)
(two M3x6 IT screws).
Damper cover
Damper L
(4) Remove the standard paper feed tray unit along the grooves on the shaft hook section, taking
care to avoid damaging the wires.
<< Precautions for reassembly >>
• Route the wires as shown in the diagram. Remember to attach a wire band.
• Install the right and left dampers correctly.
• When reinstalling the dampers, lift the standard paper feed tray slightly and align the screw posi-
tions.
Attach a band here.

1-2. Rem oval o f pa per width VR, pa per dete ction sens or, and paper si ze
d etection sensor
< Removal of paper size detection sensor >
(1) Remove the standard paper feed tray face plate. (four M3x6 binding screws)
(2) Disconnect the connector and remove the paper size detection sensor.
Fence cover
Standard paper feed tray face
Paper size detection sensor

Paper width sensor
Face plates
Lock lever
Engagement of paper width

sensor gear with rack
< Removal of paper width VR and paper detection sensor >

(1) Remove the paper guides from the right and left sides (two M3x8 screws with washers each).
(2) Remove the lock levers on the right and left fences (one E-ring each).
(3) Remove the fence cover (four M3x6 binding screws).
(4) Remove the paper detection sensor (one connector).
(5) Remove the paper width sensor (VR) together with the mounting plate (one connector, 2 M3x8
P-tight screws).The following paper sizes can be set:4
• When reinstalling the paper width sensor (VR) to the plate, keep the red lead wire about 1 mm
from the plate while tightening the nut. (Be careful to avoid damaging the sensor by excessive
tightening.)
4 - 13
HC50 00 200 5/1 2 (Rev 3.0 )
• For proper engagement of the paper width sensor gear with the rack during reassembly, mini-
mize the distance of the fences, turn the VR fully in the direction of the arrow shown in the dia-
gram, and then back off one crest from the lock position.
* After installing the paper width sensor, be sure to conduct paper width VR correction (8.4.1) in Test Mode.
2 . P i c k u p r o l l e r s h a ft
2-1.Remo val of pic kup roll er shaft (p ickup rol ler, scraper)
< Pr e - r e m o v a l >
(2) Remove the paper feed cover.
< R e m o v a l o f p ic k u p r o l l e r s h a f t >
(1) Release the lock and remove the stripper unit.
(2) Detach the scraper spring.
(3) Remove the two retaining rings from both ends of the shaft and move the two metal pieces
toward the center of the shaft.
(4) Remove the pickup roller shaft by moving it to the right, making sure that it does not hit the upper
limit sensor.
Stripper unit
Metal
Scraper spring
Pickup roller shaft Retaining ring
< R e m o v a l o f p ic k u p r o l l e r a n d s c r a p e r >
(1) Remove one retaining ring and dismount the pickup roller from the pickup roller shaft.
(2) Remove the E-rings from both ends of the scraper shaft, remove the two metal pieces, and dis-
mount the scraper shaft.

(3) Pay close attention to the collar and pulley when removing the scraper.
< >
• Note the rotating direction of the pickup roller and scraper.

• When reinstalling the pickup roller shaft, be careful to avoid striking the upper limit sensor with
the detection plate.
2-2. Rem oval o f firs t pap er feed stay assemb ly

(1) Remove the pickup roller shaft.
< Removal >
(1) Remove the first paper feed stay assembly. (three M4x8 RS-tight screws).
(Be careful of bundled wires.)
(2) Disconnect the connectors of the upper limit sensors A/B, standard paper feed tray up/down
switches, paper feed pressure sensor, and standard paper feed tray upper limit switch.Remove
the wire bands, then dismount the first paper feed stay Assy.
Paper feed tray upper safety SW connector
Standard paper feed tray up/down SW
First sheet feed stay assembly
Paper feed pressure sensor Elevator upper limit sensor B Elevator upper limit sensor A
4 - 15
HC50 00 200 5/1 2 (Rev 3.0 )
2-3.Remo val of pap er feed clutc h and pape r feed s haft
(2) Remove the top cover, then the rear cover.
(3) Raise the PCB box and keep at the raised position.
(4) Remove the pickup roller shaft.
< Removal of paper feed clutch >
(1) Remove the snap ring, disconnect the connector, and remove the paper feed clutch.
Paper feed clutch
Snap ring
Rotation stopper stay
Registration clutch Paper feed clutch
Registration brake

< Removal of paper feed shaft >
* After removing the pickup clutch, remove the paper feed shaft.
(1) Remove the shaft stay and paper feed shaft from the standard paper feed tray side (two M4x8
RS-tight screws).
(Be careful to avoid dropping the bearing.)
Paper feed shaft
Bearing
3.Elevator mechanism & bottom guide plate
3-1. Rem oval o f el evato r m otor

(1)Raise the standard paper feed tray to the upper limit position
and turn off the main power.
(2)Remove inner cover 1.
< Removal >
(1)Detach the right and left elevator springs.
(Raise the standard paper feed tray to facilitate removal.)
(2)Remove the elevator motor unit fastening screws.
(two M4x8 RS-tight screws)
(3)Remove the elevator motor holder fastening screw.
(one M4x8 RS-tight screw)
(4)Disconnect the motor connector.
Inner cover 1
(5)Hold the standard paper feed tray with one hand and remove
the elevator motor.
(Be careful of the metal pieces and shaft since they will be
detached from their installation positions.)
(Be careful to avoid dropping the standard paper feed tray.)
4 - 17
HC50 00 200 5/1 2 (Rev 3.0 )
Elevator spring
Elevator motor holder

Elevator motor

3-2. Rem oval o f bo tto m gui de pl ate
(1) Dismount the elevator motor.
(2) Remove the standard paper feed tray unit.
(3) Remove the pickup roller shaft, pickup clutch, and paper feed shaft.
(4) Remove the first paper feed stay assembly.
< Removal >
(1) Remove the lower limit frame and lower limit frame holder. (one M3x6 RS-tight screw)
Lower limit frame
Lower limit frame holder
(2) Remove the spring hook R (metal sheet located on the E side plate) from the R side. (Raise the
shaft position to facilitate removal.)(one E-ring, one M4x8 RS-tight screw)
screw
E-ring
Spring hook R
(3) Remove the two screws from the E reinforcing plate. (M4x8 RS-tight screws)
Bottom guide plate screw
E side plate on F side

E side plate on R side
E reinforcing plate Elevator shaft
4 - 19
HC50 00 200 5/1 2 (Rev 3.0 )
(4) Lift the R side. Remove the E reinforce plate and the E side plate on the R side.
(5) Remove the bottom guide plate. (six M4x8 RS-tight screws)
<< Precautions in reassembly >>
• Confirm that the flange of the bearing on the E side plate is properly positioned in the hole in the
frame.
3-3.Remo val of sta ndard pa per feed tray lo we r l imit switch

< Re m o v a l >
(1) Remove the lower limit frame and lower limit frame holder. (one M3x6 RS-tight screw)
(2) Disconnect the connector. Remove the paper feed tray lower safety switch together with the
mounting plate. (two M3x6 RS-tight screws)
Lower limit frame
Lower limit frame holder
Lower limit SW

Adjustment
1.Adjustment of the upper limit sensor position
< Adjustment >

(1) Set the pressure adjust lever to the standard position.
(2) Remove paper from the standard paper feed tray.
(3) Execute Test Mode No. 8.1.1.1 (Elevator motor) to raise and stop the standard paper feed tray
at the [Middle] position. (upper limit sensors 1 and 2 turned on)
(4) After the standard paper feed tray stops, confirm that the gap between the pickup roller and
standard paper feed tray is 1.5 to 2.0 mm.
(5) If the gap lies outside this range, turn the upper limit adjustment screw to move the upper limit
sensor assembly up or down to adjust. (Turning clockwise will lower the upper limit sensor
assembly.)
(6) After the adjustment, confirm that paper feeds correctly with the standard paper feed tray at the
top, middle, and bottom positions.
< Signs of faulty adjustment >
• If the upper limit sensor is positioned too high, increased paper feed pressure will tend to result
in multiple feeds.
• In contrast, if the sensor is positioned too low, the paper feeding process may fail to feed paper.
Upper limit adjustment screw
Pickup roller
Scraper
1.5 to 2.0 mm
Regarding Test Mode No.8.1.1.3 [Servo Action]:

• This test mode elevates the paper feed tray to the MIDDLE position (sensors 1 & 2 turned ON),
so this test mode can also be used in adjusting the upper limit sensor position.
• Since this test mode always tries to keep the paper feed tray at that position, placing a piece of
paper on the tray and adjusting the tray height from the lower position to higher position will
work. But Test Mode No. 8.1.1.1 needs to be used when lowering the tray down.
4 - 21
HC50 00 200 5/1 2 (Rev 3.0 )
2.Adjustment of stripper pressure
< Adjustment >

• According to the type of paper used, change the pressure adjustment lever position for printing.
• If multiple feeds or paper supply failures occur, adjust the paper stripper pressure.
1) If multiple feeds occur
• Turn the stripper pressure adjust knob clockwise to increase stripper pressure.
2) If paper slips and does not feed
• Turn the stripper pressure adjust knob counterclockwise to reduce stripper pressure.
Stripper pressure adjust knob
3 . P a p e r w i dt h V R c o r r e c t i o n
< Adjustment >

• Perform Test Mode No. 8.4.1 (Paper width sensor adjustment - Standard paper feed tray).
• Set the fence width to 297 mm (A3). Enter the 297 mm setting.
• After adjustment, perform Test Mode No. 8.2.2.7 (Paper). Confirm that each paper size is cor-
rectly registered.

4 . O t h e r a d j u s t m e n ts
The following adjustments and settings can be performed for each type of paper used:
4-1. Sta ndard pa per feed tray up per limi t po siti on

• Test Mode No. 5.9.*.1
• The [Upper limit sensor position adjustment] sets the top, middle, and bottom stop positions of
the standard paper feed tray. The tray upper limit position from these three can be selected for
each type of paper registered.
4-2. Sta ndard pa per feed tray po stfe ed

• This setting varies the pickup clutch Off timing and adjusts the amount of paper buckle produced
before the registration rollers.
• Equivalent test mode in different numbers exist for Trays 1 and 2 of the MTPF unit.)
4-3. Pap er feed start from stand ard pape r feed tray
• This setting varies the pickup clutch On timing.
• This test mode feature is not available for the Trays 1 and 2 of the MTPF unit.
4-4. Ass ist for stan dard pap er feed tra y

• This setting varies the paper transfer assist action on the first paper feed during the transport of
paper by the registration rollers.
• Equivalent test mode in different numbers exist for Trays 1 and 2 of the MTPF unit.
4-5. Multi ple feed d etection for sta ndard pap er feed tray
• This setting is used to enable or disable multiple feed detection.
• The sensor sensitivity adjustment is not available.
• Trays 1 and 2 of the MTPF unit use different sensor for the multiple feed detection, and that sen-
sor can be adjusted on its sensitivity
4-6. Gap between the pa pers

• Test Mode No. 5.9.*.30 varies the gap between the papers for simplex printing.
• Test Mode No. 5.9.*.31 varies the gap between the papers for duplex printing.
• These two test modes are applied not only for the paper feeding from standard paper feed tray,
but also applies to the paper feeding from the Trays 1 and 2 of the MTPF unit.
4 - 23
HC50 00 200 5/1 2 (Rev 3.0 )

M u l t i - t r a y pa p e r f e e d s e c t i o n
CHAPTER 5: Multi-tray paper feed section
CONTENTS
5-1
HC50 00 200 5/1 2 (Rev 3.0 )
Mechanisms
1.Machine configuration
1-1.Basi c structure
• The multi-tray paper feed section is comprised of the transfer unit installed in the MTPF unit and
the vertical transfer unit in the HC5000 main unit. These are two separate units.
• The MTPF unit is provided with two paper feed trays. Paper from these trays is fed by the pickup
roller, scraper, and stripper unit through the path shown in the diagram. The paper reaches the
vertical transfer unit, and is then transported to the registration roller section.
• From the registration roller section, paper is fed through the same path as when paper is sup-
plied from the standard paper feed tray.
• If paper jam occurs, the printer halts, and an error indication is displayed in accordance with the
location of the paper jam.
Jammed paper can be removed through the feed tray section, MTPF left cover, or vertical trans-
fer unit located at a lower section inside the main unit left door (gray areas shown in the diagram
below).
Registration roller section

Transport of paper from standard
Vertical transfer unit
HC5000 main unit
Paper transport unit MTPF unit
Paper feed tray No.1
Paper feed tray No.2
Stripper unit
Pickup roller
Scraper

1-2. Pap er tra nsport p ath
• The rollers (pickup roller, paper feed rollers 1 through 3) in the paper transport section inside the
base are driven by the FL transfer motor.
• The roller (paper feed roller 4) in the vertical transfer unit is driven by the FL multi feed tray
pickup motor.
• The rotation timing of each roller is controlled by a clutch. (The rollers indicated by black circles
are driven via a clutch.)
• Paper transport status is detected by FL feed sensors 1 through 4.
• The multi-tray 1 pickup sensor is provided in the paper transport path immediately after the
pickup roller for feed tray 1 only.
When A3 paper is supplied from the feed tray 1, a minor multiple feed condition may result in the
overlapping of the end section of a sheet with the leading edge of the following sheet. The multi-
tray 1 pickup sensor detects this condition. (Sensor detection is made regardless of paper size.)
• Feed sensor 3 detects the presence/absence of paper at its position and also detects multiple
feeds. (The sensor used for the detection of multiple feeds from the standard paper feed tray dif-
fers from this sensor.)
FL feed sensor 4
Paper feed roller 4
FL multi feed tray pickup motor
FL feed sensor 3
Paper feed roller 3
FL multi-tray 1 pickup sensor
FL transfer motor
FL feed sensor 2
Paper feed roller 2
FL feed sensor 1
Paper feed roller 1
FL feed sensor 3
Paper feed roller 3
FL feed sensor 2
Paper feed roller 2
FL feed sensor 1
Paper feed roller 1
5-3
HC50 00 200 5/1 2 (Rev 3.0 )
2.Paper transport section in the MTPF Unit
2-1.Paper feed tray

• The upper tray (paper feed tray 1) can hold 1,000 sheets of paper. The lower tray (paper feed
tray 2) can hold 500 sheets.
The two feed trays have identical structures, but different paper capacities.
• The right and left paper guides on each feed tray are moved simultaneously by a connecting
belt, and also have a lock mechanism.
• The paper stopper is set manually according to the paper size.
• As with the standard paper feed tray, each feed tray is equipped with a paper width potentiome-
ter and a paper size detection sensor for automatic detection of paper size.
• Similarly with the standard paper feed tray, each feed tray uses a paper detection sensor and a
paper volume sensor for detection.
2-2.F eed tray elev ating mecha nism

• The paper feed tray features a double plate structure. Only the bottom plate is raised by the ele-
vator motor.
• Each feed tray is equipped with one upper limit sensor. The upper limit position cannot be
adjusted as in the case of the standard paper feed tray system.
• As soon as the feed tray with paper is set in the machine, the corresponding FL elevator motor
activates, and its rotary force is transmitted to the joint and to the pulley shaft to wind a wire. As
a result, the bottom plate in the feed tray rises.
• The detection of the upper limit sensor halts the rising operation, thereby maintaining a constant
height during printing.
• When the feed tray is pulled out, the joint disengages. The bottom plate of the feed tray drops
due to its own weight.
• The tray set detection is made by the electrical connection and by the Safety switch.
Paper size detection sensor Insert the paper stopper here.
Paper guide
Paper guide lock mechanism

Paper volume sensor

Wire winding pulley
Engaged with motor joint
FL safety switch
FL feed tray Elevator motor
5-5
HC50 00 200 5/1 2 (Rev 3.0 )
2 -3 .Paper t r an s p o r t mec han i s m
• The transport unit is driven by the FL transfer motor via a belt.
FL transfer motor
• The transport unit has two pickup clutches that transmit drive power to the upper and lower
pickup roller shafts, and three transfer clutches that transmit drive power to paper feed rollers 1
through 3.
Clutch for paper feed roller 3
Clutch for Tray 1 pickup roller
Clutch for Tray 2 pickup roller

• Paper feed roller 3 are operated by two nip release solenoids on the R and L sides to prevent
back tension on paper during printing.
• The height of the upper limit sensor can be adjusted by turning the dial on the front side of the
main unit.
• The angle and pressure of the stripper pad can be adjusted from the front of the machine.
• The stripper pad retracts when the feed tray is pulled out, thereby preventing crumpling of paper
clamped by the stripper pad and pickup roller.
Paper feed roller 3
Nip release solenoid
Upper limit sensor height adjustment dial

(The color and the shape of the dial may differ)
Upper limit sensor
Stripper pad retracting mechanism
Stripper pad angle adjustment mechanism
Stripper pad pressure adjustment mechanism
5-7
HC50 00 200 5/1 2 (Rev 3.0 )
2-4.Vertical transfer unit
• The knob can be used to open the paper transport path and clear jammed paper.
• The paper transport path is provided with a unit comprising paper feed roller 4 and feed sensor 4
as well as two nip release solenoids.
• Paper feed roller 4 transmits the rotary force of the multi-feed tray pickup motor to transfer clutch
4.
• In addition to transport completion and nip release operation, the vertical transfer unit also oper-
ates with the registration rollers and BP to assist paper transport operations during printing.
Paper transport path open/close lever
Multi feed tray pickup motor

Transfer clutch 4
Nip release solenoid
Paper feed roller 4
Feed sensor 4
5-9
HC50 00 200 5/1 2 (Rev 3.0 )
Disassembly
1.Paper feed trays
1-1.Remo val of pap er feed tra ys

* The disassembly procedure is the same for the upper tray (paper feed tray 1) and the lower tray (paper
feed tray 2).
< Re m o v a l >
(1) Remove the cover (two M4x8 RS-Tight screws on the right side) (two P-Tight M4x8 screws on
the left side).
(2) Remove the paper feed tray from the rail (two M4x6 binding screws on the right, and three on
the left).
<< Precautions for reassembly
• While holding the feed tray on the rail to keep it from falling, lift it slightly and align the projections
with the indentations.
• Do not over tighten the tapping screws on the cover.

1-2. Rem oval o f pa per width VR (p otentiometer)

(1) Remove the four wire hanging fixtures from the bottom plate of the feed tray (two M4x6 binding
screws each).
Tray volume sensor Wire hanging fixture
(2) Disconnect the connector and remove the paper volume sensor.
(3) Lift the bottom plate and remove the plate.
Bottom plate
VR cover
(4) Remove the VR cover (one RS-Tight M4x8 screw).

(5) Remove the Paper width VR (potentiometer).
5 - 11
HC50 00 200 5/1 2 (Rev 3.0 )
• When attaching the belt, secure the right and left fences with the 6mm jig. Set the VR to the nar-
rowest width.
• The VR correction must be performed using Test Mode in the final stage of reassembly.
• Make sure that the fence cover for the bottom plate slides smoothly.
2 . P a p e r t r a n s p o r t u n i t i n t he MT P F U ni t .
2-1.Remo val of pap er tra nsport u nit

(1) Remove the MTPF rear cover.
(2) Remove the door cover from the paper transport section.
(3) Remove the MTPF left cover.
< Re m o v a l >
(1) Pull out the upper and lower paper feed trays.
(2) Remove the four stripper adjustment knobs (one binding screw M3x8 each).
Knob cover plate
Stripper adjustment knob
(3) Remove the upper and lower knob cover plates (three binding screws M4x6 for upper plate, two
binding screws M4x6 for lower plate).

(4) Pull out the four adjustment shafts (identical parts).
Adjustment shafts
(5) Disconnect the two connectors and remove the transfer motor (five M4x8 RS-tight screws).
FL transfer motor
Wires
(6) Disconnect the six connectors for the wires from the paper transport unit. Arrange the wires
neatly to avoid tangles.
5 - 13
HC50 00 200 5/1 2 (Rev 3.0 )
(7) Remove the paper transport unit (four M4x8 RS-tight screws). (Be careful to avoid damaging the
Mylar sheets on the paper transport section.)
Paper transport unit mounting screw
• Insert the stripper adjustment shaft, confirming that the knob aligns with the scale.
• When detaching or attaching the paper transport unit, slightly tilt the bottom section first and
then tilt the top section to avoid damaging the upper Mylar sheet.
3 . Ve r t i c a l t r a n s f e r u n i t
3-1.Remo val of vertic al trans fer unit

(2) Remove the bottom paper guide plate.
< Re m o v a l >
(1) Disconnect the connector and remove the Multi feed tray pickup motor (four M4x8 RS-tight
screws). (Handle the hook on the metal plate with care.)
• When installing the Multi feed tray pickup motor back on the machine, adjust its position so
that adequate backlash is given between the gears.

(2) Disconnect the three connectors for the wires from the rear side to the Vertical Transfer Unit.
Multi feed tray pickup motor
(3) Disconnect the release lever shaft from the joint (two IT M3x6 screws). (Be careful not to mis-
place the metal.)
Mounting screws on the shaft joint
5 - 15
HC50 00 200 5/1 2 (Rev 3.0 )
(4) Remove the swing plate by unscrewing the shoulder screw.
Swing plate mounting screw
(5) Remove the two vertical transfer unit retaining pins on the front side (one M4x8 RS-tight screw
each).
(6) Remove the two screws from the vertical transfer unit support shaft on the rear side (M4x8 RS-
tight screws).
Vertical transfer unit retain-

ing pins
Remove these two screws.

(7) Remove the two vertical transfer guide plate fastening screws on the left (M4x8 RS-tight
screws).
Remove the two screws
(8) Remove the screw (M4x8 RS-tight screw) from the front, then remove the Vertical transfer unit
by sliding it out of the machine through the opening from which the Standard paper feed tray was
removed.
Remove this screw.
<< Precautions for work >
• Keep in mind that once all the screws from either the Front or the Rear of the machine are
removed, the unit is supported only by the screws on the other side, potentially resulting in dis-
tortion of the unit shape.
• Since the vertical transfer guide plate is located in the paper transport path, work carefully to
avoid distorting its shape.
• The Swing plate must open when removing jammed paper. Make sure to install it in a position
where it can swing smoothly (it should hang freely).
Do not pinch and lock the Swing plate by the special shoulder screw.
Slide plate
The Swing plate
5 - 17
HC50 00 200 5/1 2 (Rev 3.0 )
4 . D i s a s s e m b l y o f o t h e r pa r ts
Removal of transfer clutches

• To remove transfer clutches 1 through 3, remove the MTPF paper transfer unit first. (During
reassembly, pay close attention to the connectors, since they are identical in the size and-
shape.)
• To remove transfer clutch 4, remove the chamber while the vertical transfer unit is still installed
on the machine.
Removal of feed sensors and multi-tray 1 pickup sensor
• To remove feed sensors 1 through 3 and the multi-tray 1 pickup sensor, remove the MTPF paper
transport unit.
• To remove feed sensor 2 and the multi-tray 1 pickup sensor, the paper transport path must be
removed from the detached MTPF paper transport unit.
• When feed sensor 3 is replaced, the sensor sensitivity must be adjusted.
• To remove feed sensor 4, remove the vertical transfer unit from the main unit first.
R e m o v a l o f M T P F e le v a t o r m o t o r
• Remove the MTPF rear cover, and remove the three mounting screws from each elevator motor
unit to dismount motor unit.

Adjustment
1.Adjustment of upper limit sensor position
< Adjustment >

(1) Open the applicable feed tray and remove the feed tray cover.
(2) Place one sheet of paper on the feed tray. With the machine power ON, close the feed tray. (The
table will rise to the upper limit position.)
(3) Check that the gap between the pickup roller and table is 0 to 1 mm.
(4) If the gap falls beyond the specified range, turn the upper limit sensor height adjustment dial to
adjust the upper limit position.
< Signs of faulty adjustment >
• If the upper limit sensor is positioned too high, increased paper feed pressure will tend to result
in multiple feeds.
• In contrast, if the sensor is positioned too low, the paper feeding process may fail to feed paper.
Scraper
Pickup roller
0 to 1 mm gap.
Table
Upper limit sensor height adjustment dial

(The color and the shape of the dial may differ)
Upper limit sensor
5 - 19
HC50 00 200 5/1 2 (Rev 3.0 )
2 . St r i p p e r a d j u s t m e n t
< Adjustment >

(1) Turn the adjustment lever to make the adjustment.
Stripper pad angle adjustment mechanism
Stripper pad pressure adjustment mechanism

3 . P a p e r w i dt h V R c o r r e c t i o n
< Adjustment method - Feed tray 1 >

• Perform Test Mode No. 8.4.2 (Paper width sensor adjustment - Feed tray 1).
• After adjustment, perform Test Mode No. 8.2.3.11 (Paper width) and check to confirm that the
width of each paper size is correctly registered.
< Adjustment method - Feed tray 2 >
• Perform Test Mode No. 8.4.3 (Paper width sensor adjustment - Feed tray 1).
• After adjustment, perform Test Mode No. 8.2.3.18 (Paper width) and check to confirm that the
width of each paper size is correctly registered.
4.Multiple feed sensor (feed sensor 3) adjustment
< Adjustment >

Check the adjustment method.
• Perform Test Mode No. 8.8.2 (Multiple feeds light intensity setting).
(The test mode automatically feeds the specified paper over the sensor. Then remove the paper
manually by hand and then press the key on the right to register the setting.)
5 . O t h e r a d j u s t m e n ts
The following adjustments and settings can be performed for each paper type:
5-1. Amo unt of p ostfeed

• Test Mode No. 5.9.1.10 (Feed tray 1), No. 5.9.1.20 (Feed tray 2)
• Adjustment of paper buckle amount in front of the registration rollers.
5-2. Ass ist

• Test Mode No. 5.9.1.11 (Feed tray 1), No. 5.9.1.21 (Feed tray 2)
• This test mode activates or deactivates the paper feed assisting action by the first paper feed
mechanism when the tip of the paper is already gripped and being transported by the Registra-
tion rollers.
5-3. Dou ble-feed detec tion timi ng.

• Double-feed detection timing can be adjusted by Test Mode No.4.2.4 (Tray-1) and No.4.3.4
(Tray-2).
Selection of the detection method for the Double-Feed, either from the 1st paper (compari-
son of the light militance value through the paper against the data pre-registered in the
machine) or from the 2nd paper (use the light militance value taken from the first sheet of
paper fed through as the data to compare the value against the succeeding papers).
• The Dragged-Feed check is selected by SE mode No.4.2.5 (Tray-1) and No.4.3.5 (Tray-2).
The Dragged-Feed is a type of double-feed in which the top-end of the succeeding paper
overlaps with the tail-end of the preceding paper while in feeding.
5 - 21
HC50 00 200 5/1 2 (Rev 3.0 )
Normally, double-feed and dragged-feed detections are selected ON/OFF in combination
by User Mode, but a selection from the operation panel using above Test Mode can be
made to activate only the dragged-feed detection when the double-feed detection is turned
OFF by the User Mode.

S e c o n d pa p e r f e e d s e c t i o n
CHAPTER 6: Second paper feed section
CONTENTS
6-1
HC50 00 20 05/12 (R ev. 3.0 )
Mechanisms
1 . M e c h a n i s m o f t h e s e c o n d pa p e r f e e d s e c t i o n
1 -1 .Paper t r an s p o r t p a t h
This section briefly halts paper sent from the first paper feed section and from the multi-tray paper
feed section at the registration rollers, then feeds it to the transfer belt unit at the appropriate time for
printing. Then either discharges the paper immediately or after duplex printing. This section is called
the second paper feed section.
The second paper feed section has the following functions:
(1) Mechanism for multiple feed detection for paper fed from the standard paper feed tray (Multiple
Feed sensor ; transmission type sensor)
(2) Sensor for detecting paper supplied to the registration rollers (Registration sensor ; reflective
sensor)
(3) Registration rollers
(4) Sensor for detecting the leading edge of the paper (Top edge sensor ; transmission type sensor)
(5) Side registration unit to center the image on each paper (CCD unit)
(6) Transfer unit for moving paper under the heads.
(7) Sensor for detecting paper moved toward the exit (Exit sensor ; reflective sensor, wider detec-
tion range than other reflective sensors)
(8) Exit unit for transport of paper for discharge
(9) Flipper unit used to move paper for duplex printing
(10) Sensor for detecting paper entering the flipper unit (Flipper sensor ; reflective sensor)
(11) Sensor for detecting paper arriving at the entrance to the duplex unit (Duplex belt IN sensor ;
reflective sensor)
(12) Duplex unit
(13) Sensor for detecting paper leaving the duplex unit (Duplex belt OUT sensor ; reflective sensor)
(14) Switchback unit to re-feed paper for duplex printing.
(15) Sensor for detecting paper entering and leaving the switchback unit (Switchback sensor ; reflec-
tive sensor)
(12)
(11)
(15)
(13) (9)
(14)
(2) (10)
(4) (5)
(8)
ＫＣＭＹ
(7)
(1) (3)
(6)
Schematic diagram of paper transport paths, as viewed from the front of the machine

P a p e r t r a n s p o rt f r o m t h e R e g i s t r a t i o n r o l l e rs t o t h e P a p e r r e c e i v i n g t r a y .
(1) The paper is fed from the standard feed tray or the multi-tray paper feeding unit and arrives at
the registration rollers. The paper is detected by the registration sensor and makes a buckle at
the registration rollers. The buckle is required to ensure correct print registration at the top.
(2) Registration clutch then activates and transfer the main motor drive to the lower registration
roller via timing belt and pulley. The paper proceeds to the next area.
(3) The top edge sensor detects the leading edge of the paper coming out through the registration
rollers. The top edge sensor triggers the print head operation, and also has a function to detect
paper jams.
(4) The paper proceeds onto the transfer unit. The transfer unit is equipped with four suction fans to
suck the paper onto the transfer belt. The suction fans keep paper firmly on the transfer belt
while the printing is in process and the paper is transported to the exit area. The transfer belt is
driven by the transfer belt motor in the transfer unit.
The print head for each color is mounted above the transfer unit and performs the printing.
The CCD installed at the entrance to the transfer unit detects the width of each paper. The value
detected by the CCD is reflected in the lateral printing position for each print head.
(5) Exit sensor is installed at the very end of the transfer unit, just before the exit unit. This sensor
detects paper coming from the transfer unit and checks whether the paper is ejected out from
the exit unit.
(6) Paper transported to the exit unit is discharged from the exit unit by a sponge roller driven by the
exit motor.
To ensure a smooth paper discharge from the exit unit, a paper ejection wing unit is installed at
the very end of the exit unit to let the paper fly out. The wing motor changes the wing position
according to the size of the paper being printed.
P a p e r t r a n s p o rt f r o m t h e f l i p p e r u n i t , b a c k t o t h e r e g i s t r a t i o n r o l l e r s ( Du pl e x
printing).
(1) For the duplex printing, Gate solenoid changes the position of the flipper gate at the tip of the
flipper unit, so that paper is guided into the flipper unit instead of being ejected straight out
through the exit unit.
(2) Before the paper reaches the duplex unit, it passes two types of sensors (Flipper sensor and
Duplex belt IN sensor), which detect paper entering and leaving the flipper unit, respectively.
The paper feed roller inside the flipper unit is driven by the main motor via pulley, timing belt and
gears.
(3) The duplex unit holds and transports the paper by its upper and lower belts. The upper and
lower belts of the duplex unit are driven by the main motor via pulley, timing belt and gears.
(4) Paper discharged from the duplex unit is sent to the switchback unit.
Switchback sensor detects paper discharged from the duplex unit. Paper from the duplex unit is
transported by the paper feed roller operated by the main motor via pulley, timing belt and gears.
It is then carried to the switchback standby position after passing over the separation claws and
carried further out by another paper transfer roller (driven by an exclusive drive motor).
(5) Paper arriving at the standby position is ready for the printing on the reverse side.
The paper is switched back under the separation claws and sent towards the registration roller.
From the registration roller, the paper goes through the same path as the simplex printing and
ejected out from the exit unit after the duplex side of the paper is printed.
6-3
HC50 00 20 05/12 (R ev. 3.0 )
M u lt i p l e f e e d d e t e c t i o n
• During the transport of paper for printing, the multiple feed sensor measures the amount of
transmitted light to check for multiple feeds. If a multiple feed occurs, printing is halted and an
error message is displayed.
• The amount of transmitted light is measured during the feeding of the first sheet, then recorded
as reference data. The amounts of transmitted light for the second and subsequent sheets are
compared to this reference data. If the amount of transmitted light differs significantly from the
reference data, a multiple feed condition is determined. (Multiple feed detection positions are dif-
ferent for the papers from the standard paper feed tray and multi-tray paper feed section.)
• Multiple feed detection can be turned On/Off separately for the standard paper feed tray and
MTPF trays 1 & 2 using [Menu 4: Function setting] on the control panel (default: On).
• Multiple feed detection timing (from the first sheet or from the second sheet) can be selected for
the MTPF trays 1 & 2. (Default: detection from the first sheet.)
• Multi-drag feed detection can be turned On or Off for the MTPF trays 1 & 2. (Default: On).
Light-receiving device (photo transistor)
Multiple feed sensor (receive)
Light-emitting device (LED)
Multiple feed sensor (send)

Mechanism of the side registration unit
• The side registration unit is equipped with CCD unit (2 pieces) to detect the lateral position of the
paper, and controls the printing positions by the print heads.
• The side registration unit is also equipped with a detection mechanism (jam detector and sen-
sor) to prevent paper from contacting the print heads and damaging the print head surfaces by
curled or dog-eared sheets. If paper contacts the jam detector bracket, due to dog-ear fold,
paper curling, etc., a sensor detects the jam and immediately stops the printing operation.
• There is a metal roller at the exit of the side registration unit for the purpose to press down on
the papers to help prevent paper from lifting up and hitting the print head surface.
CCD unit
The shape of the metal roller

Jam detector differs between an older side
registration unit and a newer unit.
CCD unit
When paper contacts the jam detector,

Jam detector
the sensor detection plate escapes out from
(The sensor is blocked by the sensor
detection plate in the normal condition). the sensor.
6-5
HC50 00 20 05/12 (R ev. 3.0 )
M e c h a n i s m o f t ra n s f e r u n i t
• The paper transfer belt is driven by the transfer belt motor.
• The roller on the unit is equipped with an encoder sensor to monitor the transfer belt drive.
• There are four suction fans installed in the unit. Two suction fans are arranged in the paper
width direction on the upstream side where the paper first enters, and two blower fans are
arranged in two rows in the longitudinal direction on the downstream side.
• A belt tension adjustment mechanism is provided. Operating this adjustment mechanism moves
the roller that applies belt tension to adjust belt skew. The adjustment method is described in a
later section.
• The cleaning roller provided on the main unit, above the end of the transfer unit, cleans the sur-
face of the transfer belt. This roller contacts the belt surface and removes ink mist which lands
on the belt. (The cleaning roller must be replaced at regular intervals.)
• Though cleaning roller is provided, the ink mist does build up between the under surface of the
belt and the top surface of the belt pate, and cause belt slippage. Periodical cleaning is needed.
Transfer belt motor
Paper transfer belt
Encoder
Paper feed
Belt plate
Belt tension adjustment mechanism
Fan
Paper feed direction

Transfer unit elevating mechanism
• The power of the main motor is transmitted to the elevating mechanism via a worm gear when
the lift gear unit clutch activates. Rotary power is transmitted directly to the drive mechanism by
the gear on one side (left side as viewed from the front) of the elevating mechanism. This drive
power is transmitted to the other side by a wire assisted by plates.
• The upper limit position (printing position) and lower limit position (position for removal of
jammed paper) are detected by separate sensors.(Transfer unit upper / lower position sensor)
• The transfer unit lifts to an appropriate print position height according to the paper thickness
entered on the panel and the pressure adjust lever position to ensure a proper gap between the
print heads and paper.
Main motor
Clutches and gears in the lift gear unit
Upper limit position detection sensor
Transfer
Beltunit
tension adjustment mechanism
When ascending
Wire Pressed by spring
Lower limit position detection sensor

Lower limit position detection sensor
Lift worm gear
Schematic diagram of the transfer unit elevating mechanism

(as viewed from the front)
When descending
Pressed by spring
6-7
HC50 00 20 05/12 (R ev. 3.0 )
M e c h a n i s m o f f li p p e r u n i t
• The flipper unit is equipped with a flipper gate function to send paper to either the exit unit or
duplex unit.
• The flipper gate is operated by Gate solenoid in the flipper unit.
• Two rollers send paper to the duplex unit. The upper roller receives the drive from the duplex
entrance roller via gear. The upper and lower rollers are synchronized by timing belt.
• Flipper sensor is mounted on the machine to confirm entry and exit of paper into and out of the
flipper unit.
• Flipper cover SW is provided on the machine to monitor the open/close condition of the flipper
unit.
Paper feed roller
Flipper gate solenoid
Flipper gate
Flipper unit
Gate solenoid
Flipper sensor
The shape and
material of the
star wheel may
differ.

Mechanism of duplex unit
• The duplex unit uses the upper and lower belts to hold and transport paper.
• The upper and lower belts are driven by gears located on the rear of the unit.
• The lower section of the duplex unit is provided with a roller to prevent the lower belt from sag-
ging due to environmental fluctuations (particularly high temperatures) that might lead to inter-
ference with other parts.
Belt slack prevention roller
Duplex unit in overturned position
Drive gear
6-9
HC50 00 20 05/12 (R ev. 3.0 )
Mechanism of exit unit
• Paper is discharged by the sponge roller and star wheel (mounted on the flipper unit).
• The sponge roller is driven by the exit motor on the exit unit. The rotation speed of the exit motor
is detected by an encoder sensor.
• Ejection wing is provided to give rigidity to paper during discharge. The wing slightly curves the
paper during ejection to give rigidity. The position of the wing is moved by the wing pulse motor.
The wing home position is detected by wing HP sensor.
Wing (front) Antistatic brush
Sponge roller
Wing (rear)
Wing motor unit Wing HP sensor
Exit motor encoder sensor Exit motor unit

1-2. Drive system for pa per transport
S c h e m a t i c d i a g r a m o f t h e p a p e r t r a n s p o rt d ri v e p o w e r t ra n s m i s s i o n s y s t e m,
v i e w e d f ro m t h e r e a r o f t h e m a c h i n e .
• Drive power from the main motor is transmitted to the paper feed rollers via timing belts.
Since a single main motor is used to drive a number of rollers, a clutch is provided for each
roller, either to engage or disengage the drive to the rollers.
• The switchback drive roll of the switchback unit is driven by a dedicated switchback motor.
• Each timing belt is provided with a tensioner to maintain proper timing belt tension. These are
self tensioners operated by spring.
Duplex roller gear Switchback motor
Duplex clutch unit
A
B
Duplex drive gear
C
Main motor
D E
Registration roller clutch unit
Idler pulley
Pickup clutch
A: Timing belt DPX (duplex belt)

B: Timing belt C-D (from clutch to duplex belt)
C: Timing belt M-C (from main motor to clutch)
D: Timing belt M-R (from main motor to registration roller)
E: Timing belt R-P (from registration roller to first paper feed)
6 - 11
HC50 00 20 05/12 (R ev. 3.0 )
S c h e m a t i c d i a g r a m o f c o r r e s p o n d e n c e b e t w e e n p a p e r t ra n s p o rt p a t h a n d
p a p e r t r a n s p o r t d r i v e p o w e r t r a n s mi s s i o n s y s t e m
The following diagram illustrates the correspondence between the rotating rollers in the sche-
matic diagram of the paper transport paths (viewed from the rear of the machine) and their drive
power transmitting systems.
C
F
E
A
ＹＭＣＫ
S c h e m a t i c d i a g r a m o f p a p e r t r a n s p o rt p a t h s a s v i e w e d f r o m t h e r e a r
C D
A
B
S c h e m a t i c d i a g r a m o f t h e p a p e r t r a n s p o rt d ri v e p o w e r t ra n s -
mission system as viewed from the rear

Disassembly
1.Registration roller upper
(1) Open front door left and right.

(2) Remove the rear cover.
(3) Remove inner cover 1 and inner cover 2 (three M4x8 binding screws).
Spring
Registration roller upper
Inner cover 1
(4) Lift the PCB box.

Loosen the right and left screws and lift the PCB box.
Using the removed screws, hold the PCB box in the raised position (right and left).
REAR LEFT
REAR RIGHT
Remove screw
Remove screw
REAR LEFT
Fasten by screw: Do the same for both the left and right.
6 - 13
HC50 00 20 05/12 (R ev. 3.0 )
(5) Remove screws and hang loose the connector bracket from the rear side (two M3x6 RS-tight
screws).
Disconnect the connector for the multiple feed sensor (receive).
Release the sensor wire harness from the harness clamps (4 locations).
(6) From the front of the machine, remove the spring hooked onto the registration roller unit upper in
the front and the rear. Then remove the mounting screw of the registration roller unit upper from
the front of the machine (one M4x5 IT screw - a short screw).
Harness clamp
Connector for multi

feed sensor (receive)
RS-tight screw
Two M3x6 screws
Harness clamps
Connector bracket
M4x5 IT screw
Connector bracket
Connector for multi feed

sensor (receive)

(7) Remove the mounting screw of the registration roller unit upper on the rear of the machine (one
M4x5 IT screw - a short screw).
(8) Before removing the registration roller unit upper from the machine, remove the bracket of the
multiple feed sensor (receive). (One M4x8 IT screw in the front. The rear is hooded onto a pin.)
The registration sensor is also attached onto the same bracket.
* Note: Work carefully to avoid damaging the paper dust cover on the multiple feed sensor
(receive).
Spring on front side Spring on rear side
M4x5 IT screw Registration roller upper
Multiple feed sensor (receive) bracket
This is the correct direction for the spring. This is incorrect direction for the spring.
If the spring is hooked in the incorrect direction as shown on the photograph on the right,
the white colored roller with the green knob in which the two springs rub against will make a
squeaky noise during the printing operation.
(9) Remove registration roller unit upper from the machine.
* Registration roller unit upper is equipped with an adjustment mechanism. For the adjustment method, refer
to the [Adjustment] in this chapter.
6 - 15
HC50 00 20 05/12 (R ev. 3.0 )
2.Registration roller lower
(1) Remove registration roller upper before performing the work.

(2) Disconnect the two connectors for the registration clutches (one is used as clutch, another is a
brake).
* Note: When reconnecting, check the identification marks (color-coded cable bands) to prevent
wrong connections (brake: blue; clutch: white).
(3) Remove the snap pin from the shaft of the registration roller lower which holds the clutches.
(4) Remove the clutch in the front, which is used as the registration brake.
Registration clutch snap pin
Registration clutch connectors
Registration brake
(5) Remove the idler pulley assembly (one M4x8 IT screw).

(6) Remove the clutch on the back, which is used as registration clutch.
Registration clutch Idler pulley assembly
Rotation prevention bracket M4x8 IT screw

(7) Remove the lift gear unit.

* Note: For the instruction on the removal of the lift gear unit, refer to the page on item: 27. Lift
gear unit.
(8) Remove registration roller L pulley.
Lift gear unit

Registration roller L pulley
(9) Remove the knob from the registration roller at the front of the machine (one M3x12 IT screw).
M3x12 IT screw
Knob
6 - 17
HC50 00 20 05/12 (R ev. 3.0 )
(10) Remove the green plastic plate with the multiple feed sensor (send) attached.
(11) Remove the bearing from the front side (one E-ring, one M4x8 IT screw).
If the bearing is difficult to remove, insert a flathead screwdriver to pry it loose.
E-ring M4x8 IT screw Bearing
Bearing Flathead screwdriver
Make sure to attach the M4x8 IT screw back on the machine after putting back the bearing (front & rear).
(12) Remove the bearing from the rear side (one M4x8 IT screw) - no E-ring on the rear.
(13) Push registration roller lower toward the rear and pull out from underneath to remove.
Registration roller lower

(14) Precautions in assembly:
• Make sure that belt 1 and belt 2 on the rear of the machine are hooked onto the shaft of registra-
tion roller lower.
* In the photograph below, belt 2 is not hooked onto the shaft of the registration roller lower.
Make sure that this type of mistake does not occur during the installation.
Belt 1
Belt 2
• When reinstalling the registration clutch on the rear of the machine against the registration roller
L pulley, be sure to align the projection and indentation and ensure proper attachment of the reg-
istration roller L pulley.
• Match the hole in the registration clutch to the D-shaped section on the shaft of registration roller
lower.
• When reinstalling the idler pulley assembly back on the machine, fit the rotation prevention
bracket section against the registration clutch.
6 - 19
HC50 00 20 05/12 (R ev. 3.0 )
3.Side registration unit
(1) Use the Test Mode on the operation panel to lower the transfer unit all the way down.
Select [Down] in [8.1.4.2 Lowering operation] to elevate down the transfer unit.
Switch OFF the power.
(2) Remove the top cover from the machine.
(3) Remove the Operation panel together with the bracket (two M4x8 IT screws).
(4) Loosen the four screws (M4x8 IT screws) on the ink bottle unit. Slide the ink bottle unit all the
way to the left.
Loosen M4x8 IT screws, two in the front and two in the rear.
Control panel
Control panel bracket
Ink bottle unit Remove M4x8 IT screws, one on the left and one on the right.
(5) Open front door L / front door R.

(6) Lift (unlock) the lever of switchback unit upper and lift the unit up.
Lever
Switchback unit upper

(7) Pull out the duplex unit.
Duplex unit
(8) Remove the print head carriage covers L and R.
Platen cover L Platen cover R
(9) Remove the print head drive PCB for the black ink.
* Note: During reassembly, make sure that the flexible hose from the head is not inserted
slanted nor loosely connected.
(10) Disconnect the connectors P151 and P155.
P155
P151
6 - 21
HC50 00 20 05/12 (R ev. 3.0 )
(11) Loosen two screws and lift the side registration unit.
These two screws hold-

ing the height position-
ing blocks should never
be loosened.
Loosen.
* The height positioning blocks will not function properly if the two screws pointed out are loosened exces-
sively. If the screws are over-loosened, tighten slightly before reinstallation.
(12) Remove the side registration unit.
Side registration unit
* CCD gain adjustment must be made after the side registration unit is replaced. For the details on the
adjustment method, refer to [item 10: CCD gain adjustment] in the adjustment section on this chapter.
* Image adjustment must also be made after replacing the side registration unit. Refer to the chapter on
which the adjustment procedure is given.
* Since external light entering into the CCD may cause error results, be sure to keep the cover in place when
checking machine operations and making adjustments on the side registration unit.

4 . Tr a n s f e r u n i t

* Note: For steps (1) through (3) above, refer to [item 1. Registration roller upper].
(4) Remove the mounting screws of the ground wire and remove the wire.
Ground wire
(5) Insert the support bar jigs. [Refer to the page on item 27: Removal of Lift gear unit.]
Jig lock pin screw
Detachment prevention
Support bar jig (2 sets)
(6) Free the wire harness from the wire saddle.

(7) Remove the mounting screw of the connector cover bracket and remove the cover bracket.
Wire saddle
Wire saddle
Connector cover bracket
6 - 23
HC50 00 20 05/12 (R ev. 3.0 )
(8) Disconnect the four connectors of the transfer unit.
Transfer unit connectors
Transfer unit connectors
(9) Lower the transfer unit manually by hand. [Refer to the page on item 27: Removal of Lift gear
unit.]
(10) Pull out the transfer unit.
* Caution: The transfer unit is heavy (approx. 15 kg). Dropping it may result in injury.
* Caution: The encoder installed in the transfer unit is a precision component. A strong blow or
shock may cause centering deviations and result in irregular paper feed speeds.

* Caution: When reinstalling the transfer unit, make sure that the transfer unit rests securely on
the front roller in the correct position, or the transfer unit may lift the maintenance unit up
too high and cause the belt to hit the print head during printing and damage the print
head.
Front roller
* When the transfer unit is replaced, check the belt tension and adjust if necessary. The adjustment method
is described in a later section.
* When replaced with a new the transfer unit, the unit may need to be adjusted so that the unit is parallel to
the registration rollers. The adjustment method is described in a later section.
* Transfer belt speed adjustment and initial paper feed motor adjustment must be performed after transfer
unit replacement. The adjustment method is described in a later section.
* Image adjustment may be required after replacing the transfer unit. Refer to the image adjustment proce-
dures in the separate chapter.
6 - 25
HC50 00 20 05/12 (R ev. 3.0 )
5 . Tr a n s f e r b e l t
(1) Remove the transfer unit.

(2) Remove the small belt retaining plates on the front and rear (two M4x8 IT screws).
(3) Remove the screws from the belt base plates on the operator’s side (four M4x8 IT screws).
M4x8 IT screws (4 pcs) M4x8 IT screw
Belt retaining plates
Belt base plates
M4x8 IT screw
M3x8 IT screw
(4) Set the transfer unit, motor down, on the transfer belt stand jig and lock the unit on the jig.
Set the unit on the jig and lock in position
(5) Remove the bearing retaining plate (two M3x6 IT screws).

(6) Remove the bearing (one M3x10 IT screw).
(7) Remove the side bracket (five M4x8 IT screws).

M3x6 IT screw Side bracket

M3x10 IT screw
Bearing
Bearing retaining plate
M4x8 IT screws (5 pcs)
(8) Pull out the transfer belt.

* Note: Check the suction fan positions. The positions of the suction fans may shift during trans-
fer belt removal/attachment. Refer to [item 8: Suction fan].
* When reinstalling the belt retaining plates, attach the rounded corners facing the inside,
towards the belt.
Rounded corners
* Caution: When reinstalling the transfer belt, make sure it is positioned left and right in parallel.
* When the transfer belt is replaced, check the belt tension and adjust if necessary. The adjustment method
is described in a later section.
* When replaced with a new the transfer belt, the unit may need to be adjusted so that the unit is parallel to
the registration rollers. The adjustment method is described in a later section.
* Image adjustment may be required after replacing the transfer unit. Refer to the image adjustment proce-
dures in the separate chapter.
6 - 27
HC50 00 20 05/12 (R ev. 3.0 )
6.Belt encoder
(1) Remove the transfer unit.

(2) Remove the belt encoder (two M3x6 IT screws).
M3x6 IT screw
Belt encoder
* In certain cases, image adjustment will need to be performed after the belt encoder has been replaced.
Check by printing out test print images of the image adjustment software and perform image adjustment if
color shifts or other abnormalities are noted. Refer to the separate chapter on the image adjustment for the
details on the adjustment.

7 . Tr a n s f e r b e l t m o t o r
(1) Remove the transfer unit from the machine.

(2) Disconnect all connectors except for the transfer belt motor connector (encoder, suction fans).
(3) Remove the transfer belt motor (four M4x8 IT screws).
Transfer belt motor
connectors
four M4x8 IT screws
* Caution: Hook the timing belt correctly when reinstalling the transfer belt motor back on the
Transfer unit.
Tension roller
* Caution: Since the exterior cover of the transfer belt motor rotates during the motor operation,
make sure that the moving part does not interfere with the cables of the belt encoder or
suction fan.
* Following the replacement of the transfer belt motor, transfer belt speed adjustment and initial paper feed
motor adjustment must be performed. The adjustment method is described in a later section.
* In certain cases, image adjustment is necessary following the transfer belt motor replacement. Check the
test print pattern using the print adjustment software and perform the image adjustment if color shifts or
other abnormalities are noted. Refer to the chapter on the image adjustment for the details on the adjust-
ment.
6 - 29
HC50 00 20 05/12 (R ev. 3.0 )
8.Suction fan
(1) Remove the transfer unit from the machine.

(2) Remove the transfer belt.
* Note: Refer to [item 5: Transfer belt].
(3) Disconnect the blower fan connector.
(4) Pull out the suction fan unit.
Suction fan unit
(5) Remove the cover from the suction fan unit.
Suction fan
Suction fan unit cover
* Note: Be careful to prevent interference from blower fan cables during reinstallation.
* Note: Check through the window to make sure that the blower fans are at the specified posi-
tions during reinstallation.
* Belt tension must be adjusted following replacement of the transfer belt. The adjustment method is
described in a later section.
* When blower fans have been replaced, the transfer unit position must be adjusted so that it is parallel to the
registration rollers. The adjustment method is described in a later section.
* In certain cases, image adjustment is necessary following blower fan replacement. Check the test pattern
and perform image adjustment if you note color shifts or other abnormalities. For a discussion of the adjust-
ment method, refer to [Adjustment] in [Ink supply passages].

9.Cleaning roller
(1) Lower the transfer unit all the way down using Test mode on the operation panel.
Select [Down] in [8.1.4.2 Lowering operation] to lower the transfer unit.
Switch off the main power.
(3) Lift the cleaning unit, push down the cleaning roller, and pull out the cleaning roller from under-
neath the cleaning unit.
* Note: Before lifting the cleaning unit, confirm that the ink pan is not positioned under the print
heads. If the ink pan is positioned under the print heads, it may strike and damage the
print heads.
Cleaning unit
Cleaning roller
Cleaning roller
* The cleaning roller needs to be replaced periodically.
6 - 31
HC50 00 20 05/12 (R ev. 3.0 )
10.Exit unit
(1) Remove the paper receiving tray from the machine.

(2) Remove the exit unit cover (two M4x8 binding screws).
Exit unit cover
M4x8 IT screw
(3) Disconnect the connectors for the wing motor, exit motor, exit motor encoder, and wing HP sen-
sor.
Wing Wing
Wing motor
M4x8 IT screw
M4x8 IT screw
M3x5 RS-tight screw
connector
Exit motor unit connector

(4) Remove the exit unit (four M4x8 IT screws).
Exit unit
10-1 .Exi t mo tor uni t

(1) Remove the exit motor unit (two M3x5 RS-tight screws).
* Note: When reinstalling the exit motor unit, let the weight of the exit motor unit apply tension to
the belt.
10-2 .Win g mot or

(1) Remove the roller motor unit.
(2) Remove the wing motor (three M3x3 RS-tight screws).
M3x3 RS-tight screw M3x3 RS-tight screw
Wing motor
* Note: When reinstalling the exit motor unit, keep the wings on the front and rear to the fully
opened position.
6 - 33
HC50 00 20 05/12 (R ev. 3.0 )
11 . Sp o n g e r o l l e r
(1) Remove the exit unit.

* Note: Refer to [item 10: Exit unit].
(2) Remove the wings from the front and rear (two M3x10 tapping screws).
(Screws are found from the bottom of the unit, with the wings opened to the widest position.)
(3) Remove the cover.
* Note: When the cover is being removed, burring of the anti-static brush will interfere with the
cover. To prevent this, open the exit unit slightly by hand during removal.
Sponge roller
Wing Cover Wing
Anti-static brush
(4) Remove the set screw and dismount the pulley.

(5) Remove the bearing. (two E-rings)
Bearing E-ring
E-ring
Pulley
Set screw
Bracket screw Sponge roller

(6) Remove the sponge roller (two bracket screws).
Sponge roller
6 - 35
HC50 00 20 05/12 (R ev. 3.0 )
12.Flipper unit
(1) Remove the paper receiving tray.

(2) Remove the exit tray unit cover.
* Note: Refer to [item 10: Exit unit].
(3) Disconnect the connector.
(4) Open the flipper unit.
Flipper unit
(5) Remove the E-rings from the front and rear.
E-ring

(6) Push the lower plates on the front and rear toward the inside and release the shafts.
Lever
(7) Pull and remove the flipper unit from the machine.
6 - 37
HC50 00 20 05/12 (R ev. 3.0 )
13.Flipper roller upper / Flipper roller lower
(1) Remove the flipper unit.

* Note: Refer to [item 12: Flipper unit].
(2) Remove the cover (four M4x8 binding screws).
* Note: Use a workbench to keep from applying excessive load onto the fragile flipper gate.
Excessive loads may result in shape distortions.
Cover Flipper roller upper
Binding screw
M4x8
Binding screw
M4x8
Binding screw
M4x8
M4x8 binding screw Flipper roller lower
(3) Remove the flipper gate unit (three M4x8 IT screws).
Flipper roller upper M4x8 IT screws (3)
Flipper gate unit
E-ring
Flipper roller lower

Cable

(4) Remove the side lever (two M4x8 IT screws).
Side lever
M4x8 IT screws (2)
* Note: When reinstalling, be careful to avoid interference with the cables.
(5) Remove the timing belt and other parts and dismount the Flipper rollers Upper and Lower. (E-
rings)
E-ring
E-ring
6 - 39
HC50 00 20 05/12 (R ev. 3.0 )
14.Duplex entrance roller
(1) Remove inner cover 3.

(2) Remove the top cover.
(6) Remove the E-ring from the front side.
E-ring
(7) Remove the pin from the pulley on the rear, remove the belt, and dismount the pulley.
* Caution: Keep in mind that the straight pin may fall out if positioned facing down.
Gear
Belt
Straight pin

(8) Remove the spacer and bearing.
Bearing
Spacer
(9) Remove the duplex entrance roller.
6 - 41
HC50 00 20 05/12 (R ev. 3.0 )
15.Duplex unit

(2) Lift (unlock) the lever of switchback unit upper and lift switchback unit upper.
Lever
(3) Pull the duplex unit to the front (forward).
Duplex unit
(4) Open up the upper duplex belt to access to the mounting screws.
(5) Remove the duplex unit by gently pushing the duplex unit toward the rear a little bit to disengage
it from the hook pins (two M4x8 IT screws).
M4x8 IT screw
M4x8 IT screw

16.Duplex belt upper
(1) Remove the duplex unit.

* Note: Refer to [item 15: Duplex unit].
(2) Remove the hinges (four M4x8 RS-tight screws).
[ The duplex unit turned up-side-down ]

Duplex belt lower
Hinge
Duplex belt upper

M4x8 RS-tight screw (2 pcs)
M4x8 RS-tight screws (2 pcs)
(3) Pull the lever forward with a finger and separate the upper belt unit from the lower belt unit.
Lever
6 - 43
HC50 00 20 05/12 (R ev. 3.0 )
(4) Remove the side covers (four M4x8 RS-tight screws).
* Caution: When reinstalling, be sure to install the right and left side covers in their original posi-
tions.
(5) Pull the belt out in the direction of the arrow.
M4x8 RS-tight screw M4x8 RS-tight screw

Side cover
Side cover
M4x8 RS-tight screw

17.Duplex belt lower
(1) Remove the duplex unit.

Refer to [item 15: Duplex unit].
(2) Remove the hinges (four M4x8 RS-tight screws).
(3) Pull the lever forward with a finger and separate the upper belt unit from the lower belt unit.
(4) Remove the side covers. (four M4x8 RS-tight screws)
* Caution: When reinstalling, do not interchange the covers for the left and right.
* Note: For steps (1) through (4), refer to [item 17: Duplex belt upper].
(5) Remove the center screw (M4x8 IT screw) and rotate the bracket 180 degrees.
M4x8 RS-tight screw
Cover Cover
M4x8 RS-tight screw Bracket M4x8 RS-tight screw
M4x8 IT screw (1 pc)
(6) Pull the belt out towards the front.
6 - 45
HC50 00 20 05/12 (R ev. 3.0 )
18.Switchback unit upper

(2) Remove inner cover 1 and inner cover 2.
(3) Pull out the pin (one M4x8 IT screw).
M4x8 IT screw (1 pc)
Pin
(4) Lift switchback unit upper slightly and remove.

When reinstalling, be sure to check the pin hole position in the back.
* Caution: Hook onto the correct pin during reassembly.

19.Switchback unit lower

(3) Lift (unlock) the lever of switchback unit upper, then lift switchback unit upper.
(4) Pull the duplex unit to the front (forward).
Duplex unit
(5) Remove the re-feed sensor bracket (one M4x8 IT screw).

* Note: Disconnect the connector first.
M4x8 IT screw
connector
Re-feed sensor bracket
6 - 47
HC50 00 20 05/12 (R ev. 3.0 )
(6) Remove the re-feed paper guide (two M3x6 IT screws).
(7) Remove the re-feed paper guide bracket (one M4x8 RS-tight screw).
(8) Remove the pin (one M4x8 IT screw).
M3x6 IT screws (2)
Re-feed sensor bracket
Pin
M4x8 RS-tight screw
M4x8 IT screw
Re-feed guide bracket

Re-feed guide
(9) Remove switchback unit lower (two M4x8 IT screws).
Switchback unit lower
M4x8 IT screws (2)
* Note: Before pulling out switchback unit lower, disconnect the connector on the rear.
* Note: When reinstalling, make sure to connect to the correct pin.

20.Switchback drive roller
* Caution: Nip pressure is applied to the switchback drive roller. Be sure to open the switchback
door to release the nip pressure before working.
* Caution: Lower the standard paper feed tray to the lowest position to prevent interference.
(3) Remove the bearing (one M4x8 IT screw).
* Note: If the bearing is difficult to remove, insert a flathead screwdriver to pry it loose.
(4) Pull the switchback drive roller toward the front to remove.
* Caution: Pull the roller straight out to prevent bending of the roller shaft.
Switchback drive roller
Bearing M4x8 IT screw (1 pc)
Bearing Flathead screwdriver
* Note: When reinstalling, match the hole on the rear side to the D-shaped section on the shaft
of the switchback drive roller.
D-shaped section
6 - 49
HC50 00 20 05/12 (R ev. 3.0 )
21.Switchback unit
(1) Remove the two IT screws (M4x8).
M4x8 IT screw M4x8 IT screw
Switchback unit
(2) To remove the switchback unit, open it and lift it out.

22.Main motor

(4) Remove the main motor (four M4x8 IT screws).
M4x8 IT screw
connector
M4x8 IT screw
M4x8 IT screw Main motor
* Note: When reinstalling, make sure that the belt separator is positioned between the two belts.
Belt separator
* Note: When reinstalling, make sure the main motor does not interfere with the cables.
6 - 51
HC50 00 20 05/12 (R ev. 3.0 )
23.Registration clutch

(2) Disconnect the two connectors.
* Note: When reconnecting, check the identification marks (color-coded cable bands) to prevent
wrong connections. (brake: blue; clutch: white)
(3) Remove the snap pin.
(4) Remove the registration brake located on the front.
Registration clutch snap pin
Registration clutch connectors
Registration brake
Paper feed clutch
Registration clutch
Connect the clutch wires to
Registration brake the correct connectors
according to the coloring.
(5) Remove the idler pulley (one M4x8 RS-tight screw).

(6) Remove the registration clutch on the back.
For steps (1) through (5), refer to steps (2) through (6) in [item 2: Registration roller lower].
* Note: When reinstalling, align the projections and indentations on the clutch and brake.

Registration clutch Idler pulley
Bracket in which the clutches M4x8 RS-tight screw

hooks on to stay stationary.
* The clutch in the back: Registration clutch ........Connector with white colored marking.
* The clutch in the front: Registration brake..........Connector with blue colored marking.
6 - 53
HC50 00 20 05/12 (R ev. 3.0 )
24.Paper feed clutch

(2) Disconnect the connector of the paper feed clutch.
Snap pin
D-shaped section
connector
Paper feed clutch
Registration clutch
Connect the clutch wires to
Registration brake the correct connectors
according to the coloring.

(3) Remove the pressure chamber.
Paper feed clutch
Pressure chamber
(4) Remove the snap pin of the paper feed clutch.

(5) Remove the paper feed clutch.
* Note: When reinstalling the paper feed clutch, match the hole in the pickup clutch to the D-
shaped section on the shaft.
6 - 55
HC50 00 20 05/12 (R ev. 3.0 )
25.Duplex clutch unit

(3) Remove the duplex clutch unit. (four M4x8 IT screws)
connector M4x8 IT screw (2 pcs)
M4x8 IT screw (2 pcs)
* Note: When reinstalling the duplex clutch unit, be sure to install the belt first.
* Note: When reinstalling the duplex clutch unit, engage its gear teeth to that of the paper re-feed
roller.
Belt

26.Multiple feed sensor (receive)

Spring
Registration roller upper
Inner cover 1

*Loosen the right and left screws and lift the PCB box.
*Using the removed screws, hold the PCB box in the raised position (right and left).
LEFT
RIGHT
Remove screw.
Remove screw.
LEFT
Lock the lifted PCB box in position by screw (Left & Right).
6 - 57
HC50 00 20 05/12 (R ev. 3.0 )
(5) Hang loose the connector bracket on the rear of the machine (two M4x8 RS-tight screws).
Remove the connector for the multiple feed sensor (receive).
Release the harness from the harness clamps (4 locations).
(6) Remove the mounting screw of the registration roller upper from the rear of the machine (one
M4x5 IT screw).
Harness clamp
Connector for multi

feed sensor (receive)
RS-tight screw
M4x8 screws (2)
Harness clamp
Connector bracket
M4x5 IT screw
Connector bracket
Connector for multi feed

sensor (receive)

(7) Unhook the springs from the registration roller upper arms, in the front and on the back.
* Note: Unhook the back spring through the opening in the front.
(8) Remove the mounting screw of the registration roller upper on the front (one M4x5 IT screw),
and remove the registration roller upper.
(9) Remove the bracket for the multiple feed sensor (receive) (one M4x8 IT screw) (front).
* Note: Work carefully to avoid damaging the paper dust cover on the sensor.
Spring on front side Spring on rear side
M4x5 IT screw Registration roller upper
Multiple feed sensor (receive) bracket
(10) Cut the cable bands and remove the multiple feed sensor (receive) from the bracket (two M3x6
RS-tight screws).
* Note: Use new cable bands to tie the wire in reassembly.
Multiple feed sensor (receive)

Cable band
M3x6 RS-tight screw (M3x6)
6 - 59
HC50 00 20 05/12 (R ev. 3.0 )
2 7 . L i ft g e a r u n i t

(3) Insert the support bar jigs from the front.
* Note: After inserting the support bar jig, rotate the shaft jigs and confirm that the jigs are locked
in position.
Safety lock pin
Safety lock pin
Support bar jig
(4) Insert an Allen wrench in the shaft of the lift gear unit on the rear of the machine and turn clock-
wise to lower the transfer unit down until the unit sits completely on the support bar jigs.
* Note: The rotation of the shaft becomes lighter when the transport unit sits on the jigs. Make
sure that the unit is sitting firmly on the support bar jigs.
down
Lift gear unit

(5) Disconnect the connector from the sensor at the bottom.

(6) Remove the sensor detection plate (one M3x6 IT screw).
(7) Remove the sensor bracket with the sensor attached (one M4x8 IT screw).
M4x5 IT screw
connector
Lift gear unit
M4x8 IT screw
Sensor detection plate
M4x8 IT screw
M4x8 IT screw Sensor bracket
M3x6 IT screw
(8) Remove the gear.

* Note: Loosen the set screw of the gear using an Allen wrench.
* Before removing the gear, remove the plastic sensor detection actuator which is screwed onto the
gear. This actuator has a play in mounting. Remove the play by rotating the actuator all the way in
Counter-Clockwise direction when mounting it back onto the gear.
* If the set screw (M6 x 20) is not in a good position to fit the Allen wrench, rotate the shaft of the lift
gear in the clockwise direction to shift the position of the set screw.
Set screw
6 - 61
HC50 00 20 05/12 (R ev. 3.0 )
(9) Remove the lift gear unit (four M4x8 IT screws).
* Note: Pay caution not to drop the small rectangular key.
Key
* Caution: Do not forget to mount the key in reassembly.

* Caution: Position the set screw, so it can be tightened at the flat portion of the D-shaped shaft.
* Caution: There is a play between the teeth of the gear removed and the teeth on the gear threaded
on the shaft. To reduce the play, push the lift gear unit diagonally down in the direction shown on the
photograph by the arrow mark. (Temporary tighten the set screw, push the lift gear unit diagonally
down and tighten the set screw.
Push down in the

direction of the
arrow.
* If the gear starts to wear out, remove the set screw, removed the gear and rotate it 180 degrees, and
then tighten the set screw back. The unused portion of the screw then can be used.

28.Multiple feed sensor (send)

(3) Disconnect the connector from the sensor.
(4) Push up the green plastic sensor plate, and then pull it diagonally down against the plate spring.
Plate spring
Connector Multiple feed sensor (send)
(5) Pull out the multiple feed sensor (send) to the front.
* The green plastic plate and the sensor is in one piece.
Multiple feed sensor (send)
6 - 63
HC50 00 20 05/12 (R ev. 3.0 )
Adjustment
List of adjustments to be made when the parts described in this chapter are replaced
List of adjustments to Transfer Transfer Belt Transfer Suction fan Machine

follow from next page unit (Sec- belt encoder belt motor (Section 8) Setup work
tion 4) (Section 5) (Section 6) (Section 7)
1.A d j u s t i n g t h e s k e w o f
tr an sfe r be lt
2.Ad justin g the t ra nsf er un it
par al l el t o t h e r e gi s t r at i on
r ol l er s
3.Tr an sf er b el t s pe ed ad j us t -
me nt
4.In itia l pa pe r fe ed mo tor
a dj u s tme nt
5.B a c k u p r o l l e r h e i g h t
6.A d j u s t i n g t h e h ei gh t of th e
pape r gu ide pla te in fr on t
of t he re gist ra tion r olle rs
7.Ad j us ti n g the p os i ti o n of
r e gi s t r at i on r ol l er u pp er
9.C omp en satio n for the
tw istin g o n the m achin e
fram e
Image adjustment (Chapter [Ink
supply passages])
: Need to check and then make the adjustment if needed.

: Basically the adjustment is not required, but do so if in need.
: Print the test pattern using the image adjustment software and make the adjustment if required.
As can be seen from above chart, replacing the listed parts may require the image adjustment.
Therefore, complete all the mechanical adjustments before doing the image adjustment.
The image adjustment should be done at the very last.
< Adjustments that must be performed in a specific sequence >

• Tra nsfer b elt sp eed ad justment -> Ini ti a l pape r feed motor ad justme nt -> Image
adju stmen t.
• Adjusting the transfer unit parallel to registration rollers -> Image adjustment.
• Adjusting the frame distortion compensation -> Image adjustment.

1.Adjusting the skew of the transfer unit belt
< Overview of adjustment >

The belt may skew due to improper tensioning of the transfer unit belt.
To prevent this, the belt skew must be properly adjusted.
Using the [8.1.3.1 Transfer Motor] function of [Drive check 8.1.3 BP Unit], operate the transfer unit
belt for about 3 minutes. Check to make sure that the edge of the belt is touching lightly against the
belt retaining plate on the operation side of the machine. The belt should not be hitting too hard
against the belt retaining plate and making a buckle. Always perform this check after replacing the
transfer unit, transfer belt, or suction fan.
< A dj u s t m e n t me t h o d >
(1) Check for belt skew and buckling.
(2) Raise the transfer unit to the printing position (use Test Mode No. 8.1.4.2 to raise the transfer
unit all the way up to the printing position. If the ink pan is positioned under the heads, the given
test mode will not activate. In such a case, move the ink pan to the right using Test Mode No.
8.1.5 before performing the above step.
Using Test Mode No. 8.1.3.1, operate the transfer unit belt in [300-3] mode for about 3 minutes.
While rotating the belt, look though from the exit end of the machine and confirm that the belt is not
skewing too far to one end so much as a buckle is made on the belt.
If a buckle is forming on the belt, make adjustment at that time.
If adjusted correctly, the belt should touch lightly against the belt retaining plate on the operator’s side
of the machine without any buckling. The belt does move up and down 0.1 to 0.2 mm in normal con-
ditions due to the belt joint.
Refer to the following pages for the method to check and to adjust.
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HC50 00 20 05/12 (R ev. 3.0 )
Check to make sure that the belt does not skew or lift on one side.
The belt should be touching lightly against the belt retaining plate on the operator’s side of the machine.
View from the exit end of

the machine.
Wing
FRONT REAR
Guide Guide
The belt should be touching lightly on the operator’s side (front).
The belt contacts the guide The belt is not touching the
too hard and lifts (make buckle). guide on the operator’s side.
Guide Belt
GOOD NO GOOD NO GOOD
GOOD NO GOOD

(3) Adjustment method
1) To check the belt skew, use Test Mode No. 8.1.3.1 and run the belt at the seed of 300 -3
drops for at least 3 minutes with the transfer unit raised to the highest (printing) position.
2) If the belt starts to slide too much to the either side, loosen the two IT screws which locks
the adjusting unit. Then rotate the adjusting screw until the edge of the belt on the opera-
tion side of the machine lightly touches the belt guide under the belt retaining plate. The
belt should not hit the belt guide too hard as to lift. The belt should only lightly touch the
guide on the operation side (front) of the machine. The adjustment should be made while
the belt is running with above test mode.
3) When the indicator is moved toward the left on the scale (clockwise turn of the adjustment
screw), the belt will move toward the front. When the indicator is moved toward the right
(counterclockwise turn of the adjustment screw), the belt will move toward the rear.
4) After the adjustment, check the belt for skew by running the belt for at least another 3 min-
utes. If the belt stays at the good position, tighten the two loosened IT screws.
5) After tightening the two screws, make a final check by running the belt for at least another 3
minutes. If the belt stays at the good position, the adjustment is completed.
Adjustment mechanism
Scale
Lock screws
< Symptom of faulty adjustment >

Improper adjustment will result in belt skew. This can cause the belt to lift, causing the paper to
scrape against the printing head and cause smudged prints.
In a worst case, the printing head may be damaged. The corner of the belt may start to tear.
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2 . A d j u s t m e n t t o p o s i t i o n t h e t ra n s f e r u n i t pa r a l l e l t o r e g i s -
tration rollers

If the transfer unit is not parallel to the registration rollers, the paper sheet whose leading edge is
aligned by the registration rollers may not run straight when transferred onto the transfer unit. As the
printing process moves to K, to C, to M, and to Y, the positions at which ink is dropped will begin to
skew (vertical skew). The adjustment described here will make the correction. This must be checked
after the transfer unit, suction fan or transfer belt is replaced, and the correction should be made
when necessary.
< Adjustment method >

(1) Check to see if adjustment is necessary.
1) Select [-M-K 1_6] in [9.2 Pattern selector] and output a test pattern from the standard paper
feed tray.(The speed should be 300-7 drops and printed in simplex). In this pattern, K and
M vertical lines are printed vertically straight. To see the condition better, A3 size matt
paper should be used. Smaller papers do not have enough distance to show the result so
good. This inspection is to see if the K and M colors are printed vertically straight or not.
There is no need for the two colors to be on top of each other. Also, there is not need to
compare the color or the darkness between the 4 vertical large strips. Looking at the
printed sheet about 60 centimeters away from the eye, if the coloring within each large strip
stays constant from top to bottom, the adjustment is good. If the coloring changes in
between, from top to bottom, the adjustment is not good.
2) If the K and M lines are parallel on the pattern output in step 1), no adjustment is needed.
Enlarged view of printed pattern
K and M parallel to each other K and M not parallel to each other

Adjustment not necessary Adjustment is necessary
* The four vertical image group can differ in color between the each. If the printing of the K and M are
made in a straight line, the color within each block should stay constantly the same.

(2) Method of adjusting to correct defects
1) Check the output pattern and determine how the adjustment mechanism should be moved.
Enlarged view of printed pattern

A B
Paper feed direction Paper feed direction
The space should be made smaller in The space should be made larger
the instruction which follows. in the instruction which follows.
Not parallel Parallel Not parallel
Registration roller and transfer unit as viewed from the top
2) Lower the transfer unit using Test Mode [8.1.4.2].

3) Measure the space using thickness gauge (feeler gauge), and memo down.
Front right section of the Transfer Unit
Gap: Approx. 1.8 mm plus/minus 0.9 mm
4) Using a 2.5-mm Allen wrench, loosen the two cap screws securing the adjustment mecha-
nism in place.
Loosen two cap screws
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HC50 00 20 05/12 (R ev. 3.0 )
5) Using thickness gauge (feeler gauge), adjust the gap wider or narrower, according to which
way the transfer unit should be shifted, referring to the previous sketch A or B.
GAP
Narrow the gap for B
Widen the gap for A
6) Using a 2.5-mm Allen wrench, tighten the two cap screws securing the adjustment mecha-
nism in place with the gap adjusted with the correct thickness gauge (feeler gauge).
7) Output the adjustment pattern again. Check the result. If the K and M lines are not parallel,
repeat the adjustment process until they are parallel.

Solid black color print pattern can also be used for the checking purpose. Use HC paper IJ (nor-
mal paper) for this purpose. Refer below for the instruction.
NO GOOD 1 NO GOOD 2
The area after the registration The area only just after the registration
roller becomes all whiter in color. roller becomes whiter in color.
[ Make the gap smaller ] [ Make the gap larger ]
GOOD

< Symptoms of incorrect adjustment >
• An error is generated during image adjustment.
• The vertical lines printed by the four colors cross each other.
* This check is required if the transfer unit, suction fan, or transfer belt is replaced. Adjustment needs to be
made according to the result of the check. After this adjustment is performed, image adjustment must be
performed. Even if the parts are not replaced, image adjustment may be necessary after this adjustment.
Check the test pattern and perform image adjustment if you note color shifts or other abnormalities. For the
detailed steps on the image adjustment, refer to the separate Chapter on the image adjustment.
* After the adjustment is made, check for the transfer belt skew by running the transfer belt for at least 3 min-
utes at the speed of 300 - 3 drops with the transfer unit raised to the highest position (printing position).
* Check that the transfer belt is not hitting the ejection guides and flipper gate. If needed, make mechanical
adjustment in those area to make the correction.
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3 . Tr a n s f e r b e l t s p e e d a d j u s t m e n t

This adjustment process monitors the transfer belt motor speed by detecting the belt encoder signal,
then automatically adjusts the speed based on a reference value. This adjustment must be performed
after the transfer unit is replaced.

(1) Select Test Mode No. [8.3.1 Belt motor speed adjustment].
(2) Select [Enter]. Entering the selection starts the transfer belt motor and initiates automatic
adjustment.
(3) The adjustment will stop automatically when completed.
* Be sure to make this adjustment before performing the [Initial paper feed motor adjustment] described next.
* After this adjustment, the image adjustment, described on another chapter, may become necessary.

4 . I n i t i a l pa p e r f e e d m o t o r a d j u s t m e n t

This adjustment synchronizes the main motor rotation speed and that of the transfer belt motor. This
adjustment should be made by observing the paper loop formed immediately after the registration
rollers.
Since an actual sheet of paper is used for this adjustment, avoid using paper with extremely high or
low rigidity. This adjustment must be performed after the transfer unit or transfer belt motor is
replaced.
* Before performing this adjustment, be sure to perform the [Transfer belt speed adjustment] described in the
previous section.
(1) Adjustment using large volumes of paper (confirmation of loop amount by continuous feeding),
* The Test Mode feeds 100 sheets of paper continuously without printing. Placing about 50 sheets on the
standard paper feed tray should be enough to complete the adjustment.
1) Select Test Mode [8.3.2 Paper feed motor initial adjustment] and activate the test mode.
2) Press the Right key to feed the paper continuously.
3) While observing the paper for the amount of loop, use the Up/Down keys to change the
value.
4) When the loop disappears, press the Enter key to register the new value setting.
Large loop: Unacceptable

Check the size of the loop at the position indi-
cated by the red border.
Small loop: Still unacceptable
No loop: OK
• If the loop is large, reduce the value.

• If the loop disappears, increase the value one step or two to make the loop again. Then
reduce the value again to make no loop.
* Since this adjustment is made while observing the loop in actual paper sheets, this method is unsuitable for
thick paper that does not produce loops, or thin paper that does not remain stable during transport. To
confirm the best result, use A3 or Ledger size papers.
* No loop could mean that the transfer belt could be rotating at a slower speed than the registration rollers.
Since that is unacceptable, always make the loop and reduce the value to make the loop disappear. This
will ensure that the speed of the main motor and the transfer belt motor is synchronized.
* By the eye, it may be difficult to judge that the loop is gone or not, as to judge No Loop is difficult.
* Print test pattern _CK4L at speed of 300 x 3 drops to confirm. This test pattern prints C and K colors in hor-
izontal lines. If the paper transfer speed changes after the registration rollers, the horizontal pitches
printed on the paper changes, making the colors within each block change. If the colors in each block
does not change, the adjustment is made correctly. If color changes can be seen within each block, the
adjustment still needs to be done.
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(2) Adjustment using smaller volumes of paper (confirmation of loop amount in single paper feed.)
* Set one sheet of paper at a time on the standard paper feed tray for this adjustment.
1) Select the same Test Mode [8.3.2 Paper feed motor initial adjustment] and activate.
2) Set one sheet of paper on the standard paper feed tray and press the key on the right to
feed the paper.
3) While observing the paper for the amount of loop, use the Up/Down keys to change the
value as you place one sheet of paper at a time on the standard paper feed tray and feed.
4) Check the amount of loop during the paper feeding operation in step 3) and adjust the
value setting until the loop disappears.
• If the loop is excessive, reduce the value.
• If no loop is found, increase the value slightly make the loop and, gradually reduce the
value to eliminate the loop.
5) Press the Enter key to register the new value setting when the loop is eliminated.
* By feeding one sheet of paper at a time from the standard paper feed tray, No Paper error message
appears after the sheet is fed. When the loop is eliminated and ready to press the Enter key to register the
new value setting, the Enter key is active even though the No Paper error message is displayed.
* Since this adjustment is made while observing the loop in actual paper sheets, this method is unsuitable for
thick paper that does not produce loops, or thin paper that does not remain stable during transport. To
confirm the best result, use A3 or Ledger size papers.
< Si g ns o f f a u l t y a d j u s t m e n t >
• Horizontal color banding occurs if the adjustment is incorrect.
• Print test pattern _CK4L at speed of 300 x 3 drops to confirm. This test pattern prints C and K
colors in horizontal lines. If the paper transfer speed changes after the registration rollers, the
horizontal pitches printed on the paper changes, making the colors within each block change. If
the colors in each block does not change, the adjustment is made correctly. If color changes
can be seen within each block, the adjustment still needs to be done.
* This adjustment is required after replacing the transfer unit or transfer belt motor. After this adjustment is
performed, image adjustment, which is described on another chapter, may need to be performed. Even if
the above parts are not replaced, image adjustment may be necessary after making this adjustment. Check
by printing the test pattern prints included in the image adjustment software, and perform image adjust-
ments if color shifts or other abnormalities are noted.

5.Adjustment of backup roller position

Adjust the height position of the backup roller according to the type of paper used.
Move the adjustment lever. Set the lever to one of the three setting positions on the inner cover.
Inner cover installation position (2 locations)
Adjustment lever in the Backup roller: Up position Backup roller: Down position
Standard center position.
Transfer unit entrance guide
Backup roller
(Operation interlocked with the transfer unit entrance guide)
Lever tilted to the right: Roller at lowered position. Lever tilted to the left: Roller at raised position.
• Adjusting position is changed according to a paper kind. (Normal paper : center position)
• The lever position adjustment may be needed for feeding different papers.
Backup roller at the center position --- Normal paper, premium paper, thin paper (lever : center)
Backup roller at the lower position --- thick paper, postcard (lever : right)
Backup roller at the upper position --- According to the state and kind of use paper (lever : left)
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HC50 00 20 05/12 (R ev. 3.0 )
6 . A d j u s t m e n t m e c h a n i s m o f r e g i s t r a t i o n r o l l e r pa p e r g u i d e

Certain types of paper may cause paper jams at the transfer unit entrance guide.
This paper guide

This adjustment is done at the factory using jigs before the machine shipment/
Therefore, this adjustment is normally not required in the field.
The adjustment is described below just to give the idea of what this adjustment is.
(1) Loosen the two RS-tight screws securing the entrance guide in place.
Screw No.1
(View from the top)
Factory default
setting1.3 mm
Screw No.1
Screw to be loosened before rotat-

ing Screw No.1. (Do the same to
the screw on the back.)
(2) Insert a thickness gauge of the desired thickness(1mm to 1.5mm) between the guide and top
surface of the Transfer unit. Adjust the gap by turning the Screw No.1 in the front and rear.
(3) After completing the adjustment, tighten the two loosened RS-tight screws.
(4) Tighten the Screw No.1 in the front and back to complete the adjustment.
* Make sure the amount of adjustment made on the front and the back is the same. If the adjustment is
incorrect, paper jamming will occur.
* Image adjustment may be necessary after this adjustment. Check the test pattern print using the image
adjustment software and perform image adjustment if judged required.

7.Adjustment of the Registration roller upper

Certain types of paper may cause problems at the registration roller section.
(1) Remove registration roller upper from the machine.
(2) Loosen the front and rear screws (IT screws) securing the adjustment mechanism in place.
(3) While observing the scale, make the necessary adjustments and tighten the loosened screws.
* Make sure the amount of adjustment is the same in the front and rear. If not, paper skewing may occur.
* This adjustment is to make the registration rollers upper and lower parallel positioning and the nipping
pressure.
* The factory uses special jig to make the adjustment. Each machine is adjusted to the best condition, thus
the default positioning (scale reading) is different for each machine.
* Before starting the adjustment, check and record the original positions on the scales of the adjust-
ment mechanisms at the front and back. If the scale positions are not recorded, the roller cannot be
returned back to its original position when required.
Adjustment mechanism
Before the adjustment, record the scale position.

If this is not recorded, the part cannot be returned to
the original position.
The screw to make the adjustment
* Image adjustment may become necessary after this adjustment. Check by using the test pattern prints
included in the image adjustment software to determine whether the image adjustment is required or not.
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8.Adjustment mechanism of registration roller guide

How the leading edge of the paper arrive at the registration rollers may affect the paper skew.
The registration roller guide height position changes where the leading edge of the paper hits against
the registration roller when the paper is fed through. The factory uses a special jig to set the height
of the registration roller guide to the best paper feeding position, which is where the registration roller
lower is 1mm plus/minus 0.1mm above the top surface of the guide.

(1) Check and record the default position of the eccentric Hexagon plate.
(2) If the Hexagon plate is turned clockwise, the guide will come to a higher position and less of the
registration roller lower will show above the guide.
(3) If the Hexagon plate is turned counter-clockwise, the guide will come to a lower position and
more of the registration roller lower will show above the guide.
counter-
clockwise
clockwise

9.Adjustment of frame distortion compensation

Due the unlevel surface of the installation site, the frame of the machine may distort. If the distortion
on the machine frame exceeds to certain level, it may affect the image adjustment made at the factory
with the machine in a flat level condition.
Use the following procedure to compensate for frame distortion caused by the floor condition.
This adjustment may be needed when the machine is installed or relocated.
The machine leveling using the four legs to the floor should be done before this adjustment.
(1) Remove paper from the standard paper feed tray and exit tray.
(5) Using a 6-mm Allen wrench, loosen the cap screws on the adjustment mechanisms (on the right
and left of the front of the machine).
(6) Tighten the two loosened cap screws (turn clockwise) until the tip of each screw just touches the
base (right and left). Then look the gap between the bottom unit of the machine and the top unit.
Excluding the three anchor plates, there should be a gap between the top unit and the bottom
unit, from the paper feed side to the paper receiving side. The gap need not be even.
Base surface on which equipment sup-

port sections (3 points) rest
Tip of cap screw
* Image adjustment may become necessary after this adjustment. Check by using the test pattern prints
included in the image adjustment software to determine whether the image adjustment is required or not.
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10.Adjustment of CCD gain on the side registration unit

This adjustment must be performed after the exchanging of the side registration unit or the CCD unit.
When the gain value of CCD is unsuitable, the abnormalities in a image of a side mask portion may
occur.
* Close all the doors and covers to prevent the CCD to catch the external light. If the CCD catches external
light, it will result in abnormal printing on the side mask area.
abnormalities in a image

(1) Start test mode.
(2) Slide the ink pan to the left (Test Mode No. 8.1.5.1) and bring down the transfer unit to the lowest
position (Test Mode No. 8.1.4.2).
(3) Set a white clean A3 paper, with no curl, on the transfer unit. (Paper with curl is unacceptable).
RISO HC Matt Paper is too white and RISO HC IJ Paper is not white enough, so these are not fit
for use. Use RISO Risograph Paper or normal copy paper which is normal white in color.
Set a A3 paper on the center of the

3rd hold on the transfer belt.
To identify the hole positions, the
holes are colored on the photo.
Set with the center axis of the roller
(4) Elevate the transfer unit to the highest position (printing position) using Test Mode No. 8.1.4.2

(5) Turn the backup roller lever (orange colored lever) to the right, so the paper is pinched by the
backup roller.
(6) Using the CCD gain adjustment Test Mode No. 8.5.2.4.1 (left) and No.8.5.2.4.2 (right), check the
present value setting. After getting into each of these two test modes, wait at least 30 seconds
for the value reading to stabilize. After the value reading stabilizes, check to see that 3-digit
value is between 240 to 250. Below or above that is no good. If the value does not stabilize
within the value of 240 to 250, change the 2-digit adjustment value (displayed above the 3-digit
value). Making the 2-digit value smaller will make the 3-digit value smaller. Making the 2-digit
value larger will make the 3-digit value larger.
(7) When the 3-digit value is adjusted to within 240 to 250, register the newly adjusted value by
using Test Mode No. 8.5.6.1.
(8) Using Test Mode, lower the transfer unit down.
(9) Return the backup roller lever to the center
(10) Remove the piece of paper from the transfer unit.
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11 . A d j u s t m e n t o f t h e F l i p p e r G a t e p o s i t i o n

If the flipper gate is not correctly adjusted in its position, the parts around the flipper gate, including
the gate may hit against the transfer belt when the flipper gate is activated by the solenoid.
If any of the parts hit the transfer belt, the position of the flipper gate must be adjusted.
The adjustment may also become necessary when the flipper unit or the flipper gate is replaced.

To make the adjustment, the flipper cover must be removed.
The adjustment will be made by the three screws shown by the RED colored arrow marks on the pho-
tograph below. The three screws shown by the BLUE colored arrow marks are the mounting screws.
(1) Loosen the three mounting screws (shown by blue arrow marks) by turning them in counter-
clockwise direction for one (1) turn each.
(2) Rotate the three adjustment screws (shown by the red arrow marks) in clockwise direction. One
rotation will move the unit out away from the transfer belt 0.7mm.
* If you are rotating the adjustment screws two turns in the clockwise direction, you must rotate the mounting
screws in the counter-clockwise direction for two turns in advance.
* All six screws must be turned in same quantity. Mounting screws in counter-clockwise direction and
adjustment screws in clockwise direction.
(3) After the adjustment screws are turned in the required amount, complete the job by tightening
the three mounting screws by turning them in clockwise direction in the same amount for all
three screws.
Adjustment Screw
Mounting screw

< C o n f i r m a t i o n a f t e r t h e a dj u s t m e n t >
• When the transfer elevates all the way up to the printing position, the wheels on the cleaning unit
should not hit the flipper gate. (The new type cleaning unit does not have the wheels, so this
confirmation cannot be done with the new type cleaning unit.)
• Confirm that neither the exit sensor nor the exit sensor bracket hit the flipper gate when the flip-
per door is opened or closed.
• Confirm that the flipper gate does not touch the transfer belt when the flipper gate solenoid acti-
vates to move the gate down toward the transfer belt in duplex printing.
After above three items to confirm are finished, make both the simplex and duplex printing to confirm
that the paper jamming problem does not occur at the flipper gate area.
Refer to the sketch on the next page to refer to the position of the gate and that of the transfer belt,
wheels on the cleaning unit and exit sensor.
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HC50 00 20 05/12 (R ev. 3.0 )
< Relative positions of the flipper gate and the parts which may hit >

Cleaning method
1 . R e m o v a l o f pa p e r d u s t
Paper dust may cause printing problems such as misfires. Clean the internal mechanisms regularly to
eliminate possible causes of printing problems.
Use a vacuum cleaner to remove paper dust.
<< Precautions in cleaning >>
• Never use an air duster, since doing so will raise paper dust, which may settle and adhere to the
nozzle surfaces of the print heads and lower the printing quality.
• Be sure to turn OFF the printer power before cleaning.
< PAPER FEED TRAY >
Paper dust tends to collect in the area (indicated

by arrow marks) close to where the corners of the
leading edge of paper are set on the standard
paper feed tray. Clean these area using a vac-
uum cleaner.
< REGISTRATION ROLLER AREA >
Paper dust also collects around registration roll-

ers. Dust accumulates especially where the side
edges of the papers transfer through. Use a vac-
uum cleaner to remove paper dust.
* Use a vacuum cleaner to remove accumulated paper
dust.
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HC50 00 20 05/12 (R ev. 3.0 )
< TOP EDGE SENSOR >
* Cleaning is recommended every 300,000. prints.
Lower the transfer belt all the way down.
Mounting screw
Remove one RS-Tight screw M4 x 8 and detach
top edge sensor, together with its bracket, from
the machine frame.
Using a cleaning paper, wipe off the dust from the

clear plastic sensor cover, especially where the
sensor receives the light.
* When the sensor is covered with dust, error message

No. X02-212 may occur.
Light receiving area
< CCD area of the SIDE REGISTRATION UNIT >
* Cleaning is recommended every 300,000. prints.
The photograph is of a CCD on the side registra-

tion unit (the unit is removed to give a clear view.
There is no need to remove the side registration
unit when cleaning).
The white area is the CCD which detects the
paper width. If this portion is dirty with paper dust
or ink residue, the side masking will become
abnormal. Wipe clean when dirty.
The CCD can be cleaned without the side regis-
tration unit removed from the machine, but for a
thorough cleaning, removing the unit from the
machine is recommended.
< EXIT SENSOR > If the exit sensor is covered with paper dust, wipe clean the sensor.
* If there are any other area of the machine found with paper dust, clean the area.

2.Cleaning the rollers
Stained rollers may cause printing problems such as dirty prints. Clean the rollers to eliminate possi-
ble causes of printing problems.
< >

• Wipe with a microfiber cloth moistened with IPA (isopropyl alcohol).
• Do not use tissue that sheds paper dust or fibers.
Wipe off ink from the rollers.
Nip roller of the flipper unit on the machine
Wipe off ink from the center portion of the

switchback roller.
* The switchback roller needs to be cleaned every
300,000. sheet printing.
Switchback section
Nip rollers Wipe off ink from the nip rollers on the machine.
Switchback door
(opened)
* Clean other rollers that are stained with ink.
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HC50 00 20 05/12 (R ev. 3.0 )
< Transfer Unit and Transfer Belt >
Reverse side of the printed paper

After repeated printing, the ink tends to build
up on the transfer belt surface & reverse side
and the large black metal plate under the belt
on the transfer unit.
* Cleaning the ink off is required after every 300,000
prints.
If the ink build up becomes bad, the ink trans-

fers on the reverse side of the printing paper.
Enlargement of the ink stain on the reverse

side of the printed paper.
On the cleaning jig, wrap cleaning wiper cloth

around the jig for the length of about 357mm of
the jig (equals to the width of the transfer belt).
* The cloth should be a microfiber type which does
not shed fiber.
Wrap cleaning wiper around the teeth
Moisten the cloth with IPA (isopropyl alcohol)

on the both surfaces of the cleaning jig.

Making sure that the power is OFF, slide the trans-

fer unit out of the machine.
* Refer to the section on the transfer unit removal for
above procedure.
Insert the cleaning jig, wrapped with IPA (isopropyl

alcohol) moistened microfiber type cloth, between
the transfer belt and the black metal guide plate.
Slide the cleaning jig back-and-forth for about 5

times.
Then rotate the transfer belt by hand and repeat
until the built up ink is removed.
If the cleaning cloth becomes dirty, replace with

new cloth, moisten with IPA (isopropyl alcohol),
and repeat.
* Depending on how much the ink is built up, the clean-
ing should be repeated about 2 to 3 times to get the ink
off the under-surface of the transfer belt and the metal
base plate.
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HC50 00 20 05/12 (R ev. 3.0 )
After the under-surface of the transfer belt is

cleaned, clean the top surface of the transfer
belt using microfiber type cloth moistened with
IPA (isopropyl alcohol).
* Do not use cloth which shed fiber.
Rotate the transfer belt by hand (rotate the pul-

ley by hand in the correct paper transfer direc-
tion) and continue with the cleaning of the top
surface of the transfer belt.
* After the under-surface and the top surface of the transfer belt is cleaned, mount the transfer unit
back in the machine.
* Mount the covers back on the machine.
* Turn ON the power.
* Using Test Mode, elevate the transfer unit to the upper most position (printing position).
* Use Test Mode No. 8.1.3.1 to run the transfer belt at speed of 300 x 3 drops for about 3 minutes and
confirm that the belt does not skew. If the belt skews, make adjustment as described earlier on this
chapter.
* Make prints and confirm that the papers are not stained by ink residue.
* If the papers get ink stain, repeat the cleaning of the belt. If no ink stain appear, the cleaning job is
completed.

I n k s u p pl y pa s s a g e s
CHAPTER 7: Ink supply passages
CONTENTS
7-1
HC50 00 20 05/12 (R ev. 3.0 )
Mechanisms
1 . M e c h a n i s m o f i n k s u p p l y pa s s a g e s
1-1.I nk su pply passa ges
Ink passages can be categorized into two main types: passages for supplying the ink required for
printing, and a waste ink passage for carrying ink used from print head cleaning.
Ink feed passages

• Ink from the ink cartridges is supplied to the print heads via reservoirs and ID units (distributors).
• Ink cartridge holder unit is equipped with a ink fuse solenoid to open and close the ink passage.
An open air is supplied to the ink cartridges at all time via an air filter.
• Each reservoir is equipped with three solenoid valves to open the reservoir to the atmosphere
(valve between reservoir and overflow tank), pressurizing (valve between reservoir and pressure
pump), and feeding ink (valve between reservoir and ink cartridge). The reservoir is provided
with a sensor to detect the presence of ink.
• The ID units distribute ink to print heads (6 print heads for each color). Two sets of ink distribu-
tors are equipped on the machine. One set of ink distributor contains two colors ink, with each
ink separated by a wall within the distributor. One set is for K and C color ink. The other set is
for M and Y color ink. The distributor for each color is equipped with a solenoid valve for the air
and a sensor to detect the ink presence. Each set of ink distributor is equipped with a heater.
• 6 pieces of print heads exist for each color in horizontal layout. There are total of 24 print heads
for the 4 colors.
• The overflow tank has a function to supply air passage for the ink reservoirs and ink distributors.
The solenoid valves open or close the air passage for each ink distribution method, such as in
normal ink distribution, compressed air ink distribution in head cleaning, etc.
• In the case when the print head is replaced or worked on during the machine setup procedure in
which the print head is not filled with ink, compressed air is needed to force the ink through the
print head.
• The YELLOW ink uses a different material for the tubing from the other color inks.
Waste ink passage
• The ink sucked by the suction pump during the head cleaning is drawn into the waste ink tank
via suction chamber. The suction chamber separates the air and the ink and only the ink goes
into the waste ink tank.
• The ink dripped into ink pan during the head cleaning goes into the waste ink tank by the gravity
through a dedicated ink tube.
• The ink which drips out from the ink cartridge from the top and bottom nozzle, during the ink car-
tridge insertion into the machine, is gathered in a pan and drawn out into the waste ink tank by
the gravity through a dedicated ink tube.
• If a problem occurs in a reservoir or ID unit and ink overflow from these units, the ink flows into
the overflow tank. In these cases, the ink flows into the overflow tank via the tube which is nor-
mally used as air passage. The overflow tank is equipped with a sensor for an ink full detection.
When this sensor detects the ink, and error message is displayed and stops the machine until a
serviceman drains the ink from the overflow tank. The ink which fills over this sensor is drawn
into the waste ink tank by gravity via dedicated ink tube.
• As described above, all waste ink collects into the waste ink tank. The full level of the waste ink
tank is detected by the full detection sensor, triggered by the weight of the waste tank and the
ink accumulated in the tank. The cleaning ink tank must be replaced periodically. The printing
condition and how often the head is cleaned will determine how often the waste ink tank has to
be replaced.

Print head (x24) Air open filter

Ink fuse solenoid
Suction chamber
Solenoid valve
ID unit 6.4mm
4mm
Ink cartridge
3mm
(x4)
Suction pump
12mm
Ink pan
4mm
Reservoir
(x4)
4mm
Tube joint
6.4mm (x8)
4mm
2mm Cleaning unit 4mm
Overflow tank
6.4mm
Solenoid valves
Pressure pump
Pressure chamber
Waste ink tank
The dimensions in the red colors represent inner
dimension of the ink and air tubes.
Schematic diagram of ink supply passages
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HC50 00 20 05/12 (R ev. 3.0 )
1-2.Mai n pa rts of the i nk feed p assages
(1) Ink fuse solenoid

The ink fuse solenoid opens the ink passage valve at the ink cartridge joints when the ink car-
tridge cover is closed.
The ink fuse solenoid opens the valve only when the ink cartridge cover is closed, and when cor-
rect ink is detected by the tag the ink flows out from the cartridge.
* If for some reason the machine operation needs to be check with the top cover of the machine removed,
the ink fuse solenoid must be manually activated to open the ink supply valve. Use plastic band or alike to
simulate the normal condition equivalent to the existence of the top cover. (Refer to the photograph.)
* Pay caution not to insert wrong color ink cartridge in wrong slot when the valve is manually opened, as the
ink immediately flows down the tube with the valve opened. The plastic band must be pulled tightly.
Ink fuse solenoid
The lock which opens the

ink flow valve.
Pushed by the cover
Operation of solenoid
Solenoid
Photo sensor
Unlock
Schematic diagram of mechanism that opens the ink flow path
Cable binder
Example of manually pressing the lock release mechanism

(2) Open air filter
• This air passage vents the ink cartridges set in the holder to the atmosphere.
• The air open passage is provided with a filter to keep dust and other particles out of the ink car-
tridges.
• The air open filter is connected to the overflow tank and opens the overflow tank to the atmo-
sphere.
• Ink that flows from the ink cartridges into the air vent tube is discharged (by gravity) into the
waste ink tank.
Air open filter
To each ink cartridge
Opens to atmosphere
Filter
Accumulated oven flown ink
Overflown ink in the filter assembly

flows down into the waste tank. Opens to atmosphere
(The tube connected to overflow tank)
The tube connects to waste ink tank
Schematic diagram of air open filter
7-5
HC50 00 20 05/12 (R ev. 3.0 )
(3) Ink reservoir
• The following diagram shows reservoir pipes and tubing for the ink and air passage. There are
total of 4 reservoirs, 1 reservoir for each color.
• The ink drain port is used to drain ink from the inside and is normally not used. It is sealed with a
cap under normal conditions. To drain ink, remove the cap and connect a tube to the port and
attach a syringe to the tube and pump the ink out. The port is an extension of a pipe that extends
down close to the bottom of the reservoir. The following page shows the internal view.
• The reservoir provides functions that opens or closes the passage to send ink to the ID unit
using compressed air from the pressure chamber, opens or closes the ink passage from the ink
cartridge and opens or closes the air vent passage.
To ID unit
Ink supply solenoid valve
Ink drain port

(Not used under normal condi-
tion)
Magnetic reed switch

Compressed air flow
Pressure solenoid valve To pressure chamber

Air open solenoid valve
Ink flow
Compressed air flow
Ink flow
Air passage To ink cartridge
Overflow ink passage
Air passage
To overflow tank Overflow ink passage

The presence of ink in the reservoir is detected by a magnet attached to the float and a magnetic reed
switch mounted outside the reservoir. Details of the float operation are given further below.
To overflow tank
To ink cartridge
Internally connected
Tip is located here.
To ID unit
To pressure chamber
Ink drain port
For ink drainage
Float Magnetic reed switch
7-7
HC50 00 20 05/12 (R ev. 3.0 )
Detection of ink cartridge replacement indication (No ink error)

The timing for the ink cartridge replacement message is determined by the ink detection mechanism
on the ink reservoir (magnet attached to a float and magnetic reed switch mounted outside the reser-
voir). The detection timing is described below.
< During printing >

During the printing, if the reservoir ink detection mechanism status changes from ink detection to no
detection, and if no ink detection status does not change for 4 seconds, the ink cartridge is deter-
mined to be empty and the ink not coming down into the reservoir. Then, the number of drops (not
dots) ejected from the print heads for each colors is counted. When the count exceeds a value of [A4
size x 30% dot density x 500 sheets], the printing operation is forcibly stopped, and an Ink cartridge
empty error is displayed. If a print job is completed before this value is reached, the Ink cartridge
empty error message is displayed when the job is finished.
< In standby mode >

If the reservoir ink detection mechanism detects no ink for 30 seconds, the Ink cartridge empty error
message is displayed.
< During head cleaning >

• In startup cleaning
If the reservoir ink detection mechanism detects no ink for 3 minutes, the Ink cartridge empty
• During other head cleaning menu

If the reservoir ink detection mechanism detects no ink for 30 seconds, the Ink cartridge empty

(4) ID unit
• Each ID unit contains two colors (K&C / M&Y), separated by an internal wall.
• Ink is distributed from ID unit to the printing heads, 6 heads to a color.
• The presence of ink in the ID unit is detected by internal float and magnetic reed switch mounted
outside the ID unit. Details of the float operation is described later on this chapter.
• Solenoid valve opens the passage to the atmosphere when ink is drawn into the ID unit.
• Ink viscosity increases at low temperatures which may cause ink misfires. As a preventive mea-
sure, the ID unit is provided with a heater. The heater warms the ID unit and the ink within the
unit. Thermistor is provided for temperature monitoring.
Thermistor
Heater
ID solenoid valve
Tubes which connect to heads

(6 tubes arranged in the same layout configu-
ration on the opposite side)
Tube to reservoir (for ink supply)
Tube to overflow tank (for air vent)
Thermistor
7-9
HC50 00 20 05/12 (R ev. 3.0 )
(5) Print head
• The machine is equipped with piezoelectric type inkjet heads. When a voltage is applied, the
piezoelectric element changes shape and causes a change in the volume of the ink pressure
chamber, resulting in ink ejection.
• The machine is provided with six modules, each of which is formed by joining two 8-gradation
318-nozzle piezoelectric type heads.
• The following shows how the nozzles are positioned in the two bonded heads.
• The two heads must be joined with high precision. The head bonding process can be performed
only at the factory. When one of the two heads in a module becomes defective, the whole mod-
ule (two bonded heads) must be exchanged.
* Never touch the nozzle surfaces of the print heads.
* Dust or scratches in the nozzle surfaces of the print heads may result in printing problems.
* In the worst case, dust and scratches on the head nozzle surfaces may result in problems (such as
misfires) that require print head replacement. To prevent such problems, avoid touching the print
head nozzle surfaces during machine maintenance. Work carefully to avoid scratching print heads
with tools or parts when working near them. Never touch or wipe the nozzle surface.
* Protect the print heads from sudden impact or shock.
* The print heads are extremely delicate components. Handle carefully and avoid dropping or hitting
them.
* If print heads are replaced, they must be adjusted.
* Adjust the physical position (mechanical adjustment) and parameters that vary among individual
heads.
< PRINT HEAD MODULE >
Head unit
Nozzle
150 dpi pitch
300 dpi pitch
Schematic diagram showing nozzle positions
Print head
Never apply impact or shock to

this area.
Nozzle surface
Avoid dust and scratches.

• Print head position adjustment mechanism
To adjust the head module angle, turn the adjustment knob in 1/8-turn increments, monitor-
ing the output result of the image adjustment software. (For more details, refer to the sec-
tion describing the image adjustment procedure.)
Each head module is secured to a head base as shown below. The head angle adjustment
mechanism mounted on the cast aluminum carriage allows the head module to swivel with
one end of the module as a pivot.
One full turn of the adjustment knob swivels the print head module about 0.03 degrees.
Pivot of rotation Head module Plate spring

Head
head angle adjustment mechanism

Adjustment knob
Base Base
Plate spring
• The various print modes are listed below. Print modes change automatically according to the
print setting by the printer driver.
Print mode Horizontal Vertical Maximum

code Resolution Resolution Number of
drops
300-7 300dpi 300dpi 7
300-6 300dpi 300dpi 6
300-5 300dpi 300dpi 5
300-4 300dpi 300dpi 4
300-3 300dpi 300dpi 3
600-7 300dpi 600dpi 7
600-6 300dpi 600dpi 6
600-5 300dpi 600dpi 5
600-4 300dpi 600dpi 4
600-3 300dpi 600dpi 3
600-2 300dpi 600dpi 2
600-1 300dpi 600dpi 1
Horizontal resolution --- Paper width-wise direction

Vertical resolution ------ Paper feed direction
Number of drops --- 0 (no ejection) to 7 drops (maximum drops)
7 - 11
HC50 00 20 05/12 (R ev. 3.0 )
(6) Overflow tank
• The pipes to the reservoirs of individual color inks are arranged as shown below.
• The overflow tank collects excess ink resulting from a problem on the reservoir, ID unit, etc.
• The air vent tubes for various components in the ink supply passages are connected to the over-
flow tank and open to the external atmosphere via the overflow tank.
• The presence of waste ink in the overflow tank is detected by the internal float and the reed
switch mounted outside the overflow tank. Details of the float operation is given later.
• The overflow tank has a waste ink drain plug. If the overflow tank becomes full, waste ink can be
drained from the tank by removing the plug and using a syringe and a tube.
To air open filter
Waste ink drain plug (plug is installed under normal conditions)
To reservoir C
(for air vent and overflow)
To reservoir K
To reservoir Y
To ID solenoid valve (K)
To ID solenoid valve (C)

To reservoir M
To ID solenoid valve (M)

To ID solenoid valve (Y)

To waste ink tank

(7) Pressure pump
• The pressure pump uses one-way valves mounted on the two tubes connected to the pump.
• The one-way valve allows air to flow in only one direction.
• The pressure pump motor moves the piston inside the pressure pump up and down via the link-
age.
• When the piston is pushed up, air inside the pump is sent to the pressure chamber (air dis-
charge) through the one-way valve (the other valve prevents air from escaping through the
intake side).
• When the piston moves down, air is drawn into the pump through the other one-way valve,
which is open to the external atmosphere (the other valve prevents air from returning back from
the pressure chamber).
• These steps are repeated to allow the pressure pump to send air to the pressure chamber.
• The pressure pump has a photo-sensor to monitor the piston operations.
• The system is also equipped with a torque limiter to keep the pressure chamber pressure from
exceeding the preset level due to pump malfunctions.
Piston up/down motion One-way valve
One-way valve
(Contains air filter) Air intake
Air discharge (external atmosphere)
(To the press chamber)
Schematic diagram of pump operation
7 - 13
HC50 00 20 05/12 (R ev. 3.0 )
(8) Pressure chamber

• The pressure chamber stores compressed air to be sent to the reservoirs.
• The pressure chamber cannot detect pressure levels. Instead, pressure levels are controlled by
the number of rotations that the piston motor makes.
• The tubes from the pressure chamber are connected to the compressed air intake solenoid
valves for the K, C, M, Y reservoirs.
• The supply of compressed air from the pressure chamber to each reservoir is controlled by the
compressed air intake solenoid valves installed on each reservoir. The solenoid valves open or
close to send compressed air according to the machine operating conditions - for example,
sending compressed air to all reservoirs at the same time (the resulting air pressure will be rela-
tively low, since air is distributed among all colors) or sending compressed air to one specific
color (air pressure is much higher when supplying compressed air to one single reservoir).
These operations are controlled by each type of head cleaning operations.
C Sends compressed air intake

solenoid valves on each reservoir
M

1-3. Main p arts in the wa ste i nk pa ssage
(1) Cleaning unit

• Six wiper-equipped suction nozzles for vacuum operation and wiping in head cleaning operation
are provided for each color, totaling 24 units (same number as the print heads) for all colors.
• During head cleaning, the suction nozzles apply vacuum suction as they sweep over the head
nozzle surfaces. A motor (cleaning motor) is provided for this sweeping operation.
• The ink pan keeps ink from the print heads from dropping onto the transfer unit. The ink pan
moves away from the location under the print heads during printing operation, then returns to
the location under the print heads after a preset time elapses after completion of a printing oper-
ation. A motor (ink pan motor) is provided for this operation.
• The cleaning unit is positioned over the transfer unit. During the head cleaning operation, the
transfer unit pushes the cleaning unit up against the printing heads. A sensor detects the height
of the cleaning unit during the head cleaning operation.
• One photo-sensor is equipped on the cleaning unit to detect the front-back movement of the
unit, and two photo-sensors are equipped on the unit to detect the side way movement.
• To guide the printing papers which transfers on the transfer unit under the cleaning unit, the
older type cleaning unit has star-wheels mounted. The newer type cleaning unit is equipped
with paper guide plates instead.
• Two torque limiters prevent ink pan motor damage when an excessive load is applied and pre-
vents side way movement of the ink pan (photograph on next page).
< CLEANING UNITS : old type & new type >
FRONT FRONT
REAR
REAR
Older type cleaning unit with star-wheels Newer type cleaning unit with paper guide plates
Photo-sensors
Suction head
Photo-sensors to detect ink pan position.
Star wheel Cap
Photo-sensor to detect suction head position.
The caps have no function and do not exist REAR OF THE MACHINE
on the newer cleaning units.
7 - 15
HC50 00 20 05/12 (R ev. 3.0 )
Torque limiter Ink pan motor
Printing Head
Ink pan
Cleaning motor Ink pan positioned below the heads
To suction chamber
Ink pan operation

Suction head operation
Flow of waste ink drawn by suction head

Photo-sensor for detecting the height position of the cleaning unit during the
cleaning operation (vacuum and sweep operation).
7 - 17
HC50 00 20 05/12 (R ev. 3.0 )
(2) Suction pump unit
• This pump generates a vacuum pressure to draw ink from the print heads through the suction
heads (24 unit in total) during the head cleaning.
• The unit has two types of sponge filters, round and rectangular in shape, to prevent ink mist from
entering the pump. In addition, an absorption sponge (pump sponge) is also installed to prevent
ink mist that enters the suction pump unit from blowing out. These filters and sponge must be
replaced periodically. (The replacement interval depends on the printing conditions, cleaning
cycle settings, head cleaning operations conducted from the panel, etc.)
Suction pump unit
Filters
Pump sponge
Pump

(3) Suction chamber
• The suction chamber separates the waste ink drawn by the suction pump unit into ink and air.
• Ink separated from air is sent to the waste ink tank (by gravity via dedicated waste ink tube).
• The presence of waste ink in the suction chamber is detected by internal float and magnetic
reed switch mounted outside the suction chamber. The detail on the float operation is given
later on this chapter.
• In normal operations, waste ink will not cause the float to rise so far as to activate the reed
switch. In such cases as when the waste ink drain tube is bent by an operational error, the float
will rise and displays an error to indicate irregular waste ink discharge.
From cleaning unit
To suction pump
To waste ink tank
Plate spring
In normal condition In vacuum operation
Discharge hole
Waste ink
Plate spring
Waste ink
Schematic diagram showing discharge of vacuumed ink
Since the plate spring is at a hanging down position in normal condition, collected waste ink is dis-
charged out through a tube into the waste ink tank.
The plate spring is pulled up by the vacuum force during vacuum operations, thus serving as a lid
and retains the waste ink as the ink is vacuumed into the suction chamber.
7 - 19
HC50 00 20 05/12 (R ev. 3.0 )
(4) Waste ink tank
• The waste ink tank receives the ink, which is accumulated in the suction chamber and ink pan of
the cleaning unit during the head cleaning.
• The waste ink tank capacity is about 6.5 liters.
• The waste ink tank holder detects when the waste ink tank reaches its maximum level.
• The ink tank holder, on which the waste ink tank is installed, is pulled up by a spring. When
waste ink accumulates into the tank, the ink tank holder starts to sink down from the weight of
the waste ink collected. Two photo-sensors monitor the position of the tank holder and detect
four conditions: No tank, Normal, Near full, and Full.
• The waste ink tank must be replaced periodically before the Full error message is displayed.
(Replacement interval depends on the printing conditions, cleaning cycle settings, head mainte-
nance operations conducted from the panel, etc.).
Waste ink tank
Spring
Joint cap
Photo sensors
Waste ink tank is not Normal condition. Near-full detection FULL detection.
detected. Machine cannot Machine operates. Machine operates. Machine cannot operate.
operate.

1-4. Mechani sms co mmon to the in k fe ed and waste ink passag es
(1) Mechanisms for detecting the presence of ink or waste ink.

The basic mechanism for detecting the presence of ink or waste ink is the same, despite some
minor differences due to the shapes of the containers such as the ink reservoir, ID unit, overflow
tank and suction chamber.
These containers each contain a float (a hollow resin object containing air) with a magnet, as
shown in the diagram below. The float elevates with the increase in the amount of the ink accu-
mulated in the container. The reed switch mounted on the exterior of these containers activate
when the switch detects the magnet, and the FULL detection is made.
Pivot of the float
Float
OFF
Clean ink or waste ink (depends on the container)
Reed switch
Magnet
Float rises due to ink or waste ink.
ON
Ink or waste ink
Schematic diagram of mechanism that detects presence of ink or waste ink
• Reservoir
Detects the presence of ink inside the reservoir. (When the reed switch remains OFF for a pre-
set duration, the ink cartridge is determined to be empty.)
• ID unit
The presence of ink inside the ID unit is detected.
• Overflow tank
Detects the overflow tank full condition.
• Suction chamber
Detects the suction chamber full condition when the waste ink within the suction chamber is not
draining out.
7 - 21
HC50 00 20 05/12 (R ev. 3.0 )
1-5.Ope rations of i nk su pply passag es
(1) Flow of the ink from the ink cartridge:

1) Four color ink cartridges are in position (ink cover is open).
(Ink cartridges tags are detected by the Receiver PCB and identified by the R/W PCB.)
2) Ink cover closing operation.
• The Ink cover sensor confirms the closing of the Ink cover.
Activates the ink fuse solenoid and opens the ink passage.
• The Ink-valve Open Sensor confirms whether the valve is actually opened.
* Under normal operating conditions with the ink cover opened, the ink passage is opened. The pas-
sage closes only when the ink cover is opened.
• The ink passage solenoid valves at the entrance of the ink reservoirs open, and also the air
vent solenoid valves on the reservoirs open.
• The ink flows into the ink reservoirs until all the reservoirs become full.
(2) Flow of the ink into the ID units via ink reservoirs:
Since the machine is shipped with the ID unit filled with ink, in normal conditions this is per-
formed at the factory before the machine shipment.
1) In the operation described in above (1), ink flows into reservoirs (under the force of gravity).
2) The ink detecting mechanism (reed switch) on the reservoirs detect the ink full level.
• The air vent solenoid valves on the ink reservoir close and at the same time the air vent
solenoid valves on the ID units open.
3) Ink flows into the ID units (free fall by the force of gravity - ink cartridge is higher than ID unit).
4) The detecting mechanisms (reed switch) on the ID units detect the ink full level.
5) The air vent solenoid valves on the ID units close.
Ink supply operation
Ink R/W PCB Ink fuse Solenoid valves on reservoirs Solenoid Reed switches for the FULL
cover solenoid valves on detection
sensor ID units
Ink pas- Air vent Com- Air vent Reservoirs ID units
sage valve pressed valve
valve air pas-
sage
valve
Machine is powered ON
- - - closed opened closed closed
Cover Tag
closed detected
activates
- - - opened opened closed closed - -
Ink flows to ink reservoir
Ink reservoir FULL detected -
open close close opened
Ink flows into ID unit
Ink ID unit FULL detected
close opened closed close
The ink reservoirs and ID units are filled with ink.

(3) Overview of operations for initial ink supply to print heads
* This operation supplies ink to the internal of each print head and must be performed when the print heads
are not filled with ink (after replacement of print heads, ID units or reservoirs). When this operation is exe-
cuted from the operation panel, the following movements are performed automatically.
* The following operations must be performed for each color. (They cannot be performed simultaneously for
all four colors at one time.)
* This is the Start-Up Cleaning.
1) The pressure pump operates and pressurizes the pressure chamber. (Pressure levels are
controlled by how many rotations the motor operates.)
2) The pressurized air solenoid valves on the reservoirs open.
3) The pressurized air forces ink to be ejected out from the print head nozzles.
4) Both the air vent solenoid valves and pressurized air solenoid valves on the reservoirs
open to bring ink pressure within the print heads down to appropriate level.
5) The suction pump performs a vacuum operation. (The suction heads sweep the print head
nozzle surfaces.)
Initial ink supply operation
Solenoid valves on Solenoid Pressure Reed Reed Suction Suction nozzles

ink reservoirs valves on pump switch on switch on pump (Cleaning unit)
ID units reservoir ID unit
Ink pas- Air vent Com- Air vent Lifts to Head
sage valve pressed valve the head cleaning
valve air pas- cleaning action
sage position
valve
opened closed closed closed - detected detected - - -
closed
pumping
Operation of pressure motor for preset duration (pressure controlled by pump operating time)
opened
Compressed air ejects ink in the reservoirs and ID units from the print heads toward the ink pan of the cleaning unit.
closed
opened opened
Solenoid valves open to reduce internal head pressure to appropriate level.
closed
opened opened (Solenoid valves open to reduce internal head pressure to appropriate level).
Vacuum Lifts to
operation position
starts
Vacuum Wipes
operation heads
continues from front
to rear.
Suction nozzles move from the front to the rear while drawing ink from print heads using vacuum force provided
by the suction pump. This completes the initial ink supply operation for the print heads.
7 - 23
HC50 00 20 05/12 (R ev. 3.0 )
(4) Head maintenance operation
There are six cleaning modes for head cleaning operations, depending on the purpose of clean-
ing.
* The processing time given on the chart below is for reference only. The Startup cleaning K/C/M/Y and
KCMY may take longer or less time depending on how much of the ink supply route on the machine is filled
with ink before the cleaning operation is started.
Cleaning mode Operation Process- Note

ing time
Normal cleaning Automatically operate for Normal cleaning About 1 For recovering from
(5.5.5) every fixed printing num- minute misfire.
ber of sheets, preset by
user mode 5.5.6
Also can be operated
from operation panel.
(All colors at one time)
Hyper cleaning Operates only by panel Hyper cleaning About 1 For recovering misfire.
(5.5.4) operation (selected color once and then minute More powerful than Nor-
only). Normal cleaning mal.
once.
The wiper cleans
the heads only
once.
Extra cleaning Operates only by panel More powerful About 2.6 For recovering misfire.
(5.5.3) operation (selected color than Hyper x 2 minute More powerful than
only). times. Hyper.
The wiper cleans
the heads twice.
Startup cleaning Operates only by panel One time Hyper About 1 Cleaning menu to use
K/C/M/Y operation (selected color cleaning after minute after replacing reservoir,
(5.5.1.1 - 5.5.1.4) only). giving extra time ID unit, print head or
for Reservoir and tubes.
ID unit to fill with
ink.
Startup cleaning Operates only by panel Twelve times About The first head cleaning
KCMY operation (All color opera- Hyper cleaning 12.5 min- menu to be used in
(5.5.1.5) tion: one by one). (3 times per color utes machine setup.
= 3 times x 4 col-
ors = 12 times.)
Flush cleaning Operates only by panel Extra cleaning About 3.5 The cleaning menu to
K/C/M/Y operation (selected color twice with piezo minutes use after the machine
(5.5.2) only). movement on the has been left unused for
Yellow heads, a long period of time.
allowing more
time for ink to
drip for the Yel-
low heads.

Disassembly
1.Bottle joint (K, C, M, Y)
In principal, the removal procedure is the same for all the colors.
The Yellow Ink uses different tube material in certain places.

(2) Pull out the cartridge of the ink color for which the bottle joint is to be replaced.
* Work carefully to avoid dripping ink.
Ink cartridge
Solenoid lever
Ink release bracket RD/WR PCB bracket
RD/WR PCB
(3) Remove the springs (2 locations).

Spring
Solenoid lever
Spring
E-ring M3x6 IT screw
7 - 25
HC50 00 20 05/12 (R ev. 3.0 )
(4) Remove the solenoid lever.
* Remove the solenoid and split pin.
Remove the solenoid lever (two M3x6 IT screws).
Split pin
(5) Remove the RD/WR PCB bracket (one M3x6 IT screw).

* The PCB is located on the other side of the wire harness core. It is best to undo the wire from the wire har-
ness clamp.
* Let the removed PCB hang loose, out of the way.
(6) Remove the E-ring (5 mm dia.) from the ink release bracket on the K ink side.
* Depending on the machine, there is a black colored plastic damper unit which gets in the way. On those
machines, remove two screws from the damper unit and remove the damper first.
(7) Remove the E-ring (5 mm dia.) from the ink release bracket on the Y ink side.
(8) Remove the ink release bracket.
Core
Cable clamp
View of K ink side IT screw M3x6
E-ring (5 mm dia.) on ink release bracket

on the Yellow Ink side.
Ink release bracket

(9) Disconnect the two tubes (from the bottle joint to be removed) shown below on the photograph
which are from the Y ink for an example.
* One is the short tube going to the ink catch pan. The other is the one which goes to the ink reservoir.
(10) Remove the bottle joint (two IT M3x6 screws).
M3x10 IT screws
Ink bottle joint to be removed

Two tubes to be removed
Note: This is to where the tube ends.
Separating the ink tube joint

(twist and pull up)
Caution in Assembly:
1) In mounting the bottle joint on the machine, rotate the bottle joint in the counter-clockwise
direction for the amount of play which exist on the screw holes and screws.
2) Never bend the tubes. Make loose loops on the tubes when directing the tubes in different
direction.
Make loose loops on the tubes

when changing the direction on
the tubes.
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HC50 00 20 05/12 (R ev. 3.0 )
3) If working on the tubes other than the Yellow Ink, make sure to hook the O-ring attached
portion of the tube onto the tube bracket. If working on the Yellow Ink tube, position the
tube so that the tube stays close to the ink catch pan, next to other tubes. Instead of the
O-ring, the Yellow Ink tube has a clip which should be hooked onto the ink catch pan.
Let the pre-shaped portion The tube for Yellow Ink, which is The O-rings on the tubes should
of the Yellow Ink tube different in material from the other hook firmly into the grooves on the
make natural curve. tubes, has a clip which should tube bracket.
hook onto the tube bracket.
4) Thread the tubes so the tubes do not tangle with the other tubes.
5) The photograph below shows the layout of the tubes when correctly positioned.
Enlarged top view of

the air open filter area

2.Receiver PCB

(2) Remove the ink cartridge from the ink cartridge holder from which the receiver PCB is to be
removed.
(3) Pull the ink cartridge holder slightly forward (two M3x6 IT screws).
* If the ink cartridge holder is pulled too much forward, the tubes from the ink pan may disconnect and
may result in ink leakage. Pay caution when pulling the ink cartridge holder forward.
M4x5 IT screw
Ink cartridge holder
M4x5 IT screw
(4) Disconnect the special cable from the Receiver PCB connection.
(5) Pinch the Receiver PCB holder in the direction of the arrow and pull out the PCB holder with the
Receiver PCB attached.
Special cable
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HC50 00 20 05/12 (R ev. 3.0 )
(6) Detach the Receiver PCB from the PCB holder.
* When reinstalling the PCB holder unit, pay close attention not to touch hard against the ink tubes
nearby, as that may cause the tubes to partially disconnect, or in worst cases the ink tubes may come
loose and spill the ink.
* Make sure that the PCB is firmly inserted into the PCB holder and the PCB holder secured firmly onto
the ink cartridge holder.
Receiver PCB

3.Ink Reservoir K / C / M / Y
The removal method is practically the same for all the colors.
The tube material for the Yellow Ink is different from the other colors.
(1) Confirm that the ink pan is positioned under the heads (if not, move the ink pan to the left, under
the heads).
(3) Disconnect the chamber tube from the pressure chamber (the tube that leads to the ink reservoir
which needs to be removed).
Reservoir Y Reservoir C Pressure chamber
Chamber tube
Reservoir M Reservoir K
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HC50 00 20 05/12 (R ev. 3.0 )
(4) Disconnect one connector for the reservoir to be removed. (The photograph below shows the
procedure for the Black Ink as an example.)
(5) Using the Black Ink reservoir as an example on the photograph below, disconnect the two tube
joints (rotate and pull).
(6) Disconnect the air vent tube of the reservoir from the overflow tank.
(7) Remove the ink reservoir (Two M3x6 IT screws).
Tube joint M3x6 IT screw
Tube joint
M3x6 IT screw
Reservoir K Connector Unplug the air vent tube from the overflow tank.
* Although the tube joint is provided with a self sealing valve, watch for ink leaks.
* Plug the ends of the unplugged air vent tube and tube from the pressure chamber into the nipples on
the reservoir to prevent dust from entering into the tubes.
Plug the ends of the two unplugged

tubes, one from the overflow tank
and the other from the pressure
chamber into the nipples on the ink
reservoir.

< Tube layout in assembly >
* Tubes to the pressure chamber.
The tubes to the pressure chamber should not be tangled.
NO GOOD: Tubes tangled.
Port
GOOD: Tubes not tangled.
Tube
Tube layout
Gap less than 2 mm
* The tubes should be laid out so they do not touch any shafts, belts and any other moving objects.
* The tubes from the ink bottle joints on the top to the tubes leading to the ink reservoir.
The tubes should be laid out so that they do not tangle with each other.
The first tube clamp for Yellow Ink. Tube clamps

(Different in location from the other colors)
7 - 33
HC50 00 20 05/12 (R ev. 3.0 )
Tubes to reservoir from the ink cartridges are positioned the same for all the colors excluding the Yellow Ink.
The photograph shows that of the M

color as an example.
Unhook the ink joint from the

bracket and route the tube from the
ink cartridge to the reservoir behind
the ink joint.
Then hook the ink joint onto the

bracket.
Enlarged view of the Yellow Ink reservoir tubing.

Enlarged view of the M, C, and K Ink reservoir tubing.
Enlarged view of the ink reservoirs of all four colors.
* Where the tubes must curve, make the loops in large diameters, so the tubes do not bend and stop the ink
flow.
* After the ink reservoir is replaced, use Test Mode 5.5.1 Start Up Cleaning for the color of the ink of
which the ink reservoir was replaced.
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HC50 00 20 05/12 (R ev. 3.0 )
4 . O v e r f l o w ta n k

(2) If the overflow tank is filled with overflown ink, empty the overflow tank of the overflown ink
before the removal by unplugging the plug on the ink draining port and connect a syringe with a
tube connected at the tip to draw the ink out of the overflow tank from the port.
(3) Disconnect the reed switch connector from the overflow tank.
(4) Disconnect the drain tube.
(5) Disconnect all the tubes from the overflow tank (9 tubes).
(6) Slide the overflow tank toward the right and lift to remove (two M3x6 IT screws).
* If the overflow tank contains waste ink, watch for ink leaks.
* Keep the overflow tank in level state all through the removal procedure.
Two M3x6 IT screws
Drain tube
Connector Overflow tank
Plug for the ink drainage when using syringe.
* The end of the tube connected to the overflow tank may stretch wide with the time. If the end opening
is stretched wide, cut off the widened end portion before reconnecting.
* The plug for the ink draining port is the 4th port form the left. Do not connect hose to this port by mis-
take.
* Whenever the overflow tank is filled with overflown ink and error message displayed, use a syringe
with a tube attached on the tip.

5.Pressure pump unit

(2) Disconnect the tube connector (1 location) by pulling it off from the other end gently.
Tube connector
(3) Disconnect the sensor connector.

(4) Remove the Pressure pump unit. (two M3x6 IT screws)
Sensor connector M3x6 IT screw
M3x6 IT screw
(5) Disconnect the motor connector.

Pressure pump unit
Motor connector Sensor connector
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HC50 00 20 05/12 (R ev. 3.0 )
6.Pressure chamber

(2) Disconnect the four tubes.
Pressure chamber
Tube
M3x6 IT screw
Tube connector
(3) Disconnect the tube connector by pulling it gently.
Tube connector
(4) Remove the press chamber (two M3x6 IT screws).

* Connect the tubes in the sequence K, C, M, Y.
* The end of the tube connected to the press chamber may stretch and become larger in the diameter
with the time. If the diameter is enlarged, trim the tip end of the tube before reconnecting.

7.ID unit / ID solenoid valve
7-1. ID unit
(1) Confirm that the ink pan is positioned under the heads (if not, slide the ink pan to left, under the
heads, using the test mode).
* Ink will drip from the print head nozzles, so the ink pan must be positioned under the heads.
(2) Place paper on top of the transfer belt to catch any ink that may land on the belt.
(5) Remove the PCB cover and raise the PCB box to the maintenance position.
(6) Remove the control panel together with the bracket, and place the control panel aside.
(7) Remove the control panel cable guide (center stay).
(9) Pull out the duplex unit from the machine and remove.
(10) Slide the ink cartridge holder to the side by loosening 4 screws.
(11) Remove one of the carriage cover of which is located over the ID unit to be removed
(12) Empty the ID unit of the ink (2 colors).
* If the ID unit is being replaced due to problem with the ink, such as ink separation or ink viscosity becoming
too thick, do not remove the ink from the ID unit in the steps described below. Removing faulty ink in the
steps described may damage (clog) the print heads. In those cases, remove the ID unit with the ink
filled, but special caution must be paid in preventing ink spillage.
* Use the filter, described below, to prevent foreign object from entering into the heads.
1) Disconnect the tube joint between the ink reservoir and the ID unit to be removed.
* If not disconnected, the ink in the ID unit will fall back into ink reservoir and the reservoir will overflow.
2) Of the air vent tube connected between the ID solenoid valve and ID unit, unplug the tube
from the solenoid valve.
3) Connect the air filter onto the tip of the unplugged air vent hose, and connect a syringe
onto the other end of the air filter, using a tube in between.
4) Using the syringe, force the ink within the ID unit out through the print heads.
5) Unplug the syringe tube from the filter, put air in the syringe again, and connect the syringe
back onto the filter and pump the ink out from the ID unit again.
6) Repeat the process until the tubes between the ID unit and print heads become empty,
checking with the eye.
* The syringe to use should be of about 20 milliliters in size. A syringe of too big of a volume may dam-
age the print heads due to too much pressure produced by the syringe.
ID solenoid valve
unplug the tube from the ID solenoid valve and con-

nect it to an air filter.
connect a syringe onto the other end of the air filter,

using a tube in between
From the syringe, with the filter between the syringe

and the ID unit, force the air out from the syringe into
the ID unit. The ink is forced out from the ID unit
out through the print head nozzles.
Filter
7 - 39
HC50 00 20 05/12 (R ev. 3.0 )
(13) From the overflow tank, disconnect the tube which leads to the ID unit (2 colors).
Tube ID solenoid valve Overflow tank
ID unit ID unit Tube
Ink joint
(14) Disconnect the connectors to the ID solenoid valves (5 connectors).
ID magnet valve
Connector
ID unit
tube
(15) Disconnect the head ribbon cables.

* Make sure that main power for the machine is turned off.
* Disconnect all 24 ribbon cables from the Ink drive PCBs for the two colors.

ID unit
tube
Valve opened
Print head
Head ribbon cable
Valve closed
Head drive PCB
(16) Close the valves on the printing heads (12 valves)

(17) Disconnect the tubes from the print heads.
(18) Remove the screw from the front side of the ID unit and remove the ID unit
(one M3x6 IT screw). There is a hook underneath the ID unit. Slide to the front to disengage
the hook.
Caution in reinstalling:
* Make sure that the valve is open when reinstalling.
* Refer to the instructions given under the Print Head removals for the cautions in connecting the Valve
onto the print head.
* The end of the tube connected to the ID solenoid valve may stretch over the time. If the end opening
has over-stretched, trim the end section before reconnecting.
* Be sure to remove paper placed on the transfer unit in the previous step before turning the machine
power ON.
* After completing the work, select the colors (2 colors) for the replaced ID unit and perform [5.5.1 Star-
tup cleaning].
NOTE: Specification on the Filter suggested for use.

Manufacturer: Sartorius Model Name: Minisart 17594-K 5.00 micrometer
7 - 41
HC50 00 20 05/12 (R ev. 3.0 )
7-2. <Removin g ID sol enoid valv e >
(1) In removing the ID solenoid valve (one piece to a color on the ID unit), disconnect the Tube joint
between the ink reservoir and the ID unit.
* If the tube joint is not disconnected, the ink from the ID unit will drop down into the ink reservoir and the ink
will overflow from the reservoir when next step, described bellow, is performed.
(2) Disconnect a connector and remove two mounting screws (IT M3x6 screws) to dismount the
solenoid valve. Disconnect the air vent hoses from the solenoid valve.
Ink Joint

8.Print head
The print heads are very fragile and vulnerable to impact and shock. Pay attention to the following
when handing the print head.
* Do not drop the print head. The print head surface will be damaged, and the piezo mechanism will also be
damaged.
* Prevent the print head surface (the nozzle portion) from touching any surface after taking the head out of
the machine.
* Never lay anything on top of the print head.
* When transporting the print head, use the special print head shipment container in which a print head is put
in when ordered as a spare part, and place it in the container correctly.
* Avoid from hitting the nozzle surface against the print head carriage when installing the print head on the
machine.
* To prevent print head damage from static electricity, be sure to wear an antistatic wrist band when touching
print heads. If antistatic wrist band is not available, touch the machine metal frames firmly with both hands
before working to let the static electricity escape from the body.
(1) Confirm that the ink pan is positioned under the heads (if not, slide the ink pan under the heads
using Test Mode). Place paper on top of the belt to catch any ink that may drip from the heads.
(3) Remove the control panel together with the bracket and put the panel aside.
(4) Remove the control panel cable guide (beam).
(5) Pull out the duplex unit and detach it from the machine.
(6) Remove the carriage cover.
* Depending on the ink color, the Ink cartridge holder unit may have to be slid toward the paper feeding
side to access to the screws to remove the carriage cover.
(7) Remove the head ribbon cables from the head drive PCB for the print head to remove.
(8) Disconnect print head tube from the print head to remove.
* Be sure to close the valve before disconnecting the print head tube.
Disconnect other print head tubes if they interfere.
Valve closed Valve opened
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HC50 00 20 05/12 (R ev. 3.0 )
(9) After removing the screws with washers, lift the head straight up (two M3x23 screws with wash-
ers).
The screw to be removed the first in removal.

The screw to be tightened the last in mounting.
The two screws to remove.
The screw to be removed the last in removal.

The screw to be tightened the first in mounting.
Do not touch this screw.
Print head
M3x23 screw with washer M3x23 screw with washer
Lift the print head

straight up, and be
careful to avoid acci-
dentally pulling the
other ribbon cables.
Ribbon cable
* The print head is a precision device. Avoid impact or shock on the head.
* Do not disconnect the ribbon cables which are connected the print head.
* Be careful to avoid scratching the nozzle surfaces.
* To prevent print head damage from static electricity, be sure to wear an antistatic wrist band when
touching print heads. If antistatic wrist band is not available, touch the machine metal frames firmly
with both hands before working to let the static electricity escape from the body.

Caution in assembly:
* Clean the print head and the surroundings free of spilled ink. But never wipe the nozzle surface.
Use lint-free/dust-free cloth or paper. Never use cloth or paper which emits lint or dust.
Uncleaned dripped ink will eventually drop down onto the transfer belt and get on the printing papers.
* Use a torque driver to tighten the screws (two M3x23 screws with washers) securing the head in
place to ensure the correct tightening force and to minimize the possibility of damaging the screw
slots. The tightening torque is 9.0 kgf-cm (0.9 N-m or 90 cN-m).
*
Example of setting the torque driver

to 9.0 kgf-m (0.9 N-m or 90 cN-m)
The setting method varies depending on the manufacturer and model. Refer to the
instructions provided with the torque driver.
* Make sure that the print head is correctly fit on the carriage before screwing it firmly on the carriage.
Otherwise the head will be mounted raised on the carriage and will not print correctly.
* Before inserting the valve back on the print head, check that the O-ring on the valve is in good cond-
tion. Worn or broken O-ring will cause ink leakage, or lets air in and cause ink to drop back into the
ink reservoir and cause ink overflow.
* The valve should be pushed gently but firmly and into the print head by rotating it slightly back and
forth as pushed in. When correctly inserted back on the print head, the valve should rotate freely on
the head. If incorrectly inserted, the valve will not rotate as freely. If incorrectly inserted, pull the
valve out again and check for any damage on the O-ring. If no damage on the O-ring, try putting it
back on the head again.
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HC50 00 20 05/12 (R ev. 3.0 )
* Make sure that all the ribbon cables are connected back in the correct slot on the head drive PCB,
firmly and straight. The head drive PCB will be damaged by short-circuit if the ribbon cable connec-
tion is not done correctly.
Example of ribbon cable not fully inserted
Example of ribbon cable not inserted straight
* Mount back the carriage covers back on the machine, paying attention not to jam on the ribbon
cables and pull the cables out.
* Make sure that the carriage covers are mounted before putting the duplex unit back on the machine.
Otherwise the duplex unit will catch the ribbon cables and rip the cables.
* Remove the papers from the transfer belt before turning the machine power back ON.
* After the print head is replaced, use Test Mode 5.5.1 [Start Up Cleaning] and select the ink color of
the print head and activate to clean the head.
* Print test pattern using print adjustment software to check to see if print adjustment is necessary or
not. Refer to the print adjustment procedure to follow on this chapter if adjustment is necessary.

9.Head drive PCB

(3) Pull out the duplex unit and remove from the machine.
(4) Remove the carriage cover.
(5) Disconnect the connectors (2 locations) on the rear end of the head drive PCB.
* Depending on the machine, there is one more connector to disconnect on the front end of the PCB for the
K and Y print head PCBs.
(6) Disconnect the head ribbon cables (12 locations).
(7) Remove the screws from the head drive PCB bracket and dismount the PCB together with the
bracket (two M3x6 IT screws).
M3x6 IT screws
REAR Connectors FRONT
(8) Remove the screws from the Head driver PCB bracket (two M3x6 IT screws), and dismount the
PCB from the bracket.
Head drive PCB bracket M3x6 IT screws
Head drive PCB
* Check carefully to make sure that the ribbon cables from the heads are not inserted loosely or at an
angle. Improper insertion of the ribbon cables will result in short-circuit and damage the PCB.
* Be careful not to pull the ribbon cables when putting the carriage cover back on.
* While working on the head drive PCB, hands will touch on the print head tubes. Touching the tubes
will result in misfires in printing (white lines). After all the parts are mounted back on, do Normal Head
Cleaning once.
7 - 47
HC50 00 20 05/12 (R ev. 3.0 )
10. Cl eanin g u nit
(1) Lower the transfer unit all the way down and turn OFF the machine power. If the power is
already off with the transfer unit not all the way down, rotate the lift gear unit shaft to lower the
transfer unit.
(3) Remove inner cover 3 to access to the cleaning unit.
(4) Put papers on top of the transfer belt to protect the belt from the ink which may drip.
Bracket M4x8 IT screw

M4x8 IT screw Bracket
Tube
Lift gear unit shaft
Connector Tube
Cleaning unit
(5) Disconnect the cleaning unit connector at rear left of the machine.
Bracket
M4x8 IT screw
M4x8 IT screw Bracket
Tube
Connector
Cleaning unit Cleaning motor

(6) Disconnect the two tubes, one from the ink pan and the other from the suction chamber, on the
rear of the machine. The one from the ink pan should be unplugged from the Y shaped connec-
tor located close to the K ink reservoir.
Work carefully to avoid dripping ink.
Insert the tube from the ink pan into the bracket (indented section) on the cleaning unit to secure
the tube in place.
(7) Remove the 4 brackets, 2 in front and 2 in rear, by removing one IT screw M4x8 from the each.
M4x8 IT screw
M4x8 IT screw
Bracket
Cleaning unit Bracket
(8) Pull the cleaning unit out along the railing.
7 - 49
HC50 00 20 05/12 (R ev. 3.0 )
* Be careful to avoid the drain tube from falling off from the bracket on which it is hooked onto, or the ink will
start to spill out from the tube.
Cautions in assembly:
* Due to a lack of grease on the shaft, shown on the photograph, too much load is put on the ink pan
motor, and may display error message [S04-300: Ink pan motor time-out]. To prevent this problem,
apply grease on the shafts as judged necessary. Make sure that the grease does not get on the suc-
tion head when applying.
* As it was when removing the unit out, also watch out during the assembly to avoid the drain tube from
falling off from the bracket on which it is hooked onto, or the ink will start to spill out from the tube.
* When connecting the bellow-shaped large hose onto the left rear side of the maintenance unit, wipe
clean the surface of the nozzle on the maintenance unit and inner surface of the hose. If a film of ink
is present on either of the two pieces, that makes it very easy for the hose to come off from the main-
tenance unit during machine operations. That will cause ink to spill out of the machine from the main-
tenance unit. The same with the other hose from the ink pan disconnected from Y shaped connector.
Wipe clean the inner surface of

the hose and the outer surface
of the plastic tubing.
* Do not forget to remove the papers from the transfer belt before turning ON the machine power.

11 . S u c t i o n h e a d
(1) Remove the cleaning unit.

(2) To remove the suction head, push it down gently and open the hook that holds it in place.
* Take care to prevent the spring from springing out.
* Do not widen the hook too much, as that may crack the hook.
* After attaching the suction head, check that the suction head does not lean.
If the suction head leans, remove it once and attach it back on again. If attached on correctly, the
suction head should elevate up-and-down freely when pushed down by finger.
* If the suction head leans, poor suction of ink is caused and ink may drip and fall from the print head,
and the suction head may fall off after hitting the print head.
Suction head
Spring
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HC50 00 20 05/12 (R ev. 3.0 )
12.Cap
(1) Remove the cleaning unit.

(2) To remove the rectangular rubber cap, push it down and open the hook securing it.
* Take care to prevent the spring from springing out.
* Do not widen the hook too much, as the hook may break off.
Note:
The cap has no function. It was originally designed for a purpose which later decided not to use.
Cap
Spring

13.Suction chamber

(3) Remove the IT screw (one M3x6 IT screw).
(4) Disconnect tube 1.
Tube 2 Suction chamber
Connector
M3x6 IT screw
Tube 1
Tube 3
(5) Disconnect tube 2 and plug it to where tube 1 was plugged in, to prevent ink leakage from the
tube.
(6) Disconnect tube 3 from the ST. TANK and connect it to the tube connector nipple on the suction
chamber to prevent ink from leaking out the tube.
Wipe the inside of the tube and outer rim of the plastic pipe
when reconnecting, as film of ink on those surfaces will make
the pipe to come off easily during machine operation.
ST.TANK
Tube 2 Tube connector nipple
Tube 3
7 - 53
HC50 00 20 05/12 (R ev. 3.0 )
(7) Remove the suction chamber by pulling it forward and lifting.
* Be careful to avoid bending the drain tube during reassembly. Bending the tube will stop the waste ink
flow.

1 4 . I n k c a t c h pa n
(1) Remove the ink release bracket (refer to page 7-25).

(2) Unplug the four ink drain tubes from the ink catch pan (one tube per color).
(3) Wipe clean the ink on the ink catch pan.

(4) Disconnect the drain pipe from the bottom of the ink catch pan.
* Watch out for the ink dripping.
(5) Unhook the O-ring portion of the tubes from the ink catch pan.
(6) Remove mounting screws (two IT M4x8 screws) from the ink catch pan and remove the pan.
The difference between the former machine and newer machine on how the Yellow Ink tube is
attached on the ink catch pan. (Also refer to page 7-28 for detail.)
The newer type machine with clear tube for

Yellow ink tube has additional tube holding
slots added.
7 - 55
HC50 00 20 05/12 (R ev. 3.0 )
1 5 . Wa s t e i n k ta n k
(1) Open waste ink tank access door on the front bottom of the machine.
(2) Turn the knob screw and remove the waste ink tank cover.
(3) Remove the cap from the waste ink tank.
* Turn the cap over and hang it on the waste ink tank holder.
Waste ink tank cap
Waste ink tank cover Knob screw

* When reinstalling the waste ink tank, press down on the waste ink tank holder before setting the tank
in place.
Waste ink tank holder
* The waste ink tank must be replaced periodically.

1 6 . Wa s t e i n k ta n k h o l d e r
(1) Open waste ink tank access door on the front bottom of the machine.
(2) Turn the knob screw and remove the waste ink tank cover.
(3) Remove the PS7R controller.
(4) Remove the waste ink tank.
(5) Pull out the waste ink tank holder from the front of the machine. (Two M4x8 screws with wash-
ers)
Waste ink tank holder
M4x8 screw with washer
(6) Disconnect the sensor connectors (2 locations) from the waste ink tank holder.
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HC50 00 20 05/12 (R ev. 3.0 )
1 7 . S u c t i o n p u m p u n i t , p u m p f i l t e r, p u m p s p o n g e
(1) Remove the MTPF rear cover.

(2) Remove the MTPF rear cover bracket (one M4x5 screw with washer).
Base cover bracket
(3) Disconnect the tube.

Cable band Suction pump unit
Tube
Cable band
Base cover bracket
(4) Remove the connector cable from the upper side of the MTPF and disconnect the connectors (2
locations).
(5) Remove the cable bands (2 locations).
Connector
Cable band

(6) Pull the suction pump unit forward to remove (two M4x8 screws with washers).
Suction pump unit
(7) Remove the suction pump cover (three M4x8 IT screws).
M4x8 IT screw
Suction pump cover
M4x8 IT screw
7 - 59
HC50 00 20 05/12 (R ev. 3.0 )
(8) Remove the pump filter.
* When replacing filters, be sure to replace both the large and small filters as a set.
Filter (large)
Filter (small)
(9) Remove the pump sponge from the suction pump cover.
Pump sponge
* The pump sponge must be replaced periodically.

Adjustment
1 . A d j u s t m e n t a ft e r p r i n t h e a d r e p l a c e m e n t
After replacing print heads, two types of parameters specific to each head must be set and image
adjustments made (physical head positions and print timing depending on combination of heads).
Make these adjustments according to the procedures described below.
1-1. Parameter setti ng

Enter the two types of parameters (voltage and AL type) specific to each print head for proper opera-
tion in this printer.
The parameter values are indicated on the print head and print head packaging.
Enter the indicated parameter values by following the procedure described after the photograph.
E x a mp l e o f re p l a c e me n t o f
Check before installation and record as necessary.
C6 head
From machine rear side, the heads
are numbered 1, 2, 3, 4, 5, and 6.
Since the C6 head has been replaced,

enter data on the input screen for the
C61/C62 head. (The parameters to be
entered are indicated on the head and
package.)
207/211
AL2/3
< Voltage >
C61•••20.7V C62•••21.1V
<AL>
C61•••+2 C62•••+3
Entering parameters from the control panel

Using Test Mode [8.5.1.1 Voltage] and [8.5.1.3 AL type], select the replaced print head and enter
the values indicated on the print head, as shown above. Then press the Enter key to save the
new parameter settings in the NVRAM mounted on the ORIP PCB.
Download the saved parameters from the NVRAM onto the ORIP PCB as a backup by using
Test Mode [8.5.6.1 Store Adj. Config.].
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HC50 00 20 05/12 (R ev. 3.0 )
1-2.Preparation for the image adjustment
Arrange the tools and instruments required to make the adjustment.
Head angle jig
Reference chart for scanner calibration
Notebook PC (commercially available) running

image adjustment utility software
USB 2.0 x2 equipment is necessity.
Flatbed scanner (commercially available)

Recommended scanner: Canon CanoScan D1250U2
Epson ES-7000H
One USB extension cable and one USB 2.0 cable, both com-
mercially available.
Loupe (magnifier) to check the printed image quality.
Paper for image adjustment Approximately 20 sheets of A4

coated paper, and A3 coated paper. Paper for print test
Approximately 20 sheets of A4 plain paper.
Connect the notebook PC to the machine using the USB extension cable, and notebook PC to the
flatbed scanner using USB 2.0 cable.
* Use USB 2.0 cable. USB 1.1 cable will not work properly.
1-3. Con nection o f USB cabl e from the m achine to Laptop PC.
(1) Disconnect PS7R controller from HC5000 (disconnect all the connections).
(2) Connect USB extension cable to the USB cord from the ORIP PCB and pug to PC.

1-4. Installation metho d of the USB dri ver
Installing special HC5000 USB driver in a PC is necessary to use the image adjustment software.
Install the USB driver beforehand in the following procedures.
From CD-R etc. supplied, save following two files in one folder in the laptop PC.
• olytest.sys
• olytest.inf
(1) Turn ON the printer (HC5000).
(2) Connect the extended USB cable from the ORIP PCB to the laptop PC.
(3) The wizard of installation of the USB driver starts. Operate the laptop PC according to the wiz-
ard.
(4) Choose “olytest.inf” which was saved in a folder in laptop PC.
(5) Complete installation according to the wizard.
1-5. Set up metho d of auto imag e adj ustmen t so ftware

From CD-R etc. supplied, copy the folder on the laptop PC in which the auto image adjustment soft-
ware is contained.
When using the program, double click the execution file (***.exe) in this holder.
* If the property of the saved holder is displayed as [reading only], when copied from CD-R, cancel the prop-
erty of [reading only]. When write-in operation is carried out into this holder during program operation, if it
is [reading only], the image adjustment operation ends in error.
* The USB driver, described previously on item 1-4 above, must be pre-installed to continue with the image
adjustment.
* Use the fresh set of software for each image adjustment by downloading the software each time from the
CD-R.
1-6. Set up metho d of manua l ima ge ad justm ent s oftware

From CD-R etc. supplied, copy the folder on the laptop PC in which the auto image adjustment soft-
ware is contained.
When using the program, double click the execution file (***.exe) in this holder.
* If the property of the saved holder is displayed as [reading only], when copied from CD-R, cancel the prop-
erty of [reading only]. When write-in operation is carried out into this holder during program operation, if it
is [reading only], the image adjustment operation ends in error.
* The USB driver, described previously on item 1-4 above, must be pre-installed to continue with the image
adjustment.
1-7. Image adju stmen t proced ure

(1) Make sure that the PS7R controller is completely disconnected from HC5000.
(2) Turn machine power ON and check that the panel displays, [Waiting for data].
(3) Warm-up the machine by following the procedure given on item 1-8 on next page.
(4) Operate normal cleaning of the print heads to ensure no misfire exists.
(5) Connect PC to HC5000 and also to the scanner.
(6) Start the PC used for adjustment and launch the image adjustment software.
(7) Using the calibration reference chart, perform scanner calibration.
(8) Start the auto image adjustment software and make adjustments following the instructions on
the PC display.
(9) The adjustment result is automatically saved on the NVRAM mounted on the ORIP PCB.
(10) Do not input Test Mode [8.5.6.1 Save Adj. Config.] yet.
(11) Print image check test pattern image from the image adjustment software.
(12) If and only if the result of the adjustment is satisfactory, use Test Mode [8.5.6.1 Save Adj. Con-
fig.] to save the adjusted values on the ORIP PCB as a backup.
7 - 63
HC50 00 20 05/12 (R ev. 3.0 )
1-8.W arm -up o peratio n for the trans fer belt
Before image adjustment, perform a warm-up operation for the transfer belt according to the proce-
dures described below to ensure stable transport operations.
(1) Confirm that the machine is in normal operating condition, mechanically well adjusted.
(2) Make sure that the machine is levelled good on the floor.
(3) Using Test Mode, slide the ink pan to the right, raise the transfer unit all the way up to the print-
ing position, run the transfer belt for one minute at speed of 300x7 drops.
(4) After one minute of warm-up operation, stop the belt and go out of the test mode menu.
1-9.Setting adjus tment patterns on the flatbed scanne r

When placing the calibration reference chart, coarse adjustment pattern, density adjustment pattern,
or fine adjustment pattern on the flatbed scanner, make sure to place them accurately on the scanner
glass.
Set at the top corner of the chart on the corner of the glass.
If after scanning, the error display on the

PC says, “Cannot detect image pattern”,
the chart needs to be trimmed (cut)
0.5mm or more so on the correct side of
the chart, so the scanner can scan the full
A4 size image of the charts.
Chart placed face down.
(This normally occur in scanning the
printed chart image as the adjustment
proceeds.)
Refer to item 1-10 on page 7-65 for
another method to get the image on the
center of the paper.
CanoScan LiDE 35, 40, or 50
Calibration chart This corner of the chart is placed on the top corner of the scanner.
TOP
BOTTOM
The thick line is the bottom of the chart.

1-10 .Pl acing the A4 size Matte Paper corre ctly on the feed tray
Place clean sheets of A4 Matte Papers (coated paper) on the Standard paper feed tray of HC5000.
Make sure that the side guides on the tray is positioned flat against the side of the papers.
If the printed image does not land on the center of the sheets, making it difficult for the scanner to
read full image on the chart, place a spacer on one side of the Standard paper feed tray, against the
inner surface of the paper side guide. This will shift the printed image to one side, and assist the
printed image to land on the center of the paper. The width of the spacer may vary according to how
much the image is shifted. It is normally 0.5 to 1.0mm, so the spacer should be thin.
The paper flat against the paper side guide. A spacer placed between the paper and
the side guide to compensate the print
image shifting on the paper.
* In which side the spacer is to be placed depends on which side the image is shifting
* The spacer should be put in position so that it does not feed into the machine with the paper.
7 - 65
HC50 00 20 05/12 (R ev. 3.0 )
1-11. Exec utio n of Auto Im age Adju stment
Scanner calibration
(1)Turn the machine power ON.

(2)Start the PC for adjustment and launch the
Auto Image Adjustment software.
(3)Select the scanner to be used for image
adjustment.
(4)From the main menu, select [Scanner cali-
bration].
(5)Click [Next]
(6)Place the calibration reference chart on the

scanner, making sure that the chart is posi-
tioned correctly. Then Click [Next].
The thick line is the bottom of the chart.
(7)Click [Exit] to return to the main menu.

Image adjustment
(1)Place A4 Matte paper (coated paper) on the

Standard paper feed tray in A4R direction
(horizontal direction).
(2)Set sleep function OFF (5.8.1). Return it to
the original setting after the adjustment is
completely finished.
(3)Set Image area (4.10) to maximum.
Return it to the original setting after the
adjustment is completely finished.
(4)Start the PC for the adjustment and launch
the image adjustment software.
Keep in mind that HC5000 must be in [Ready]

(print mode ON) state all though the adjustment
to make prints in each step. If during each step
HC5000 is not in [Ready] (print mode OFF) sta-
tus, press the green Start button on HC5000
operation panel to keep the machine in [Ready]
status.
(5)Click [Next].
(6)Click [Print].
* Three sheets of coarse adjustment pattern will be
printed.
(7)Click [Next].
* Make sure that the printed pattern outputs show no
misfire. If you note misfires, conduct the normal
cleaning procedure once, click [Back], and click
[Print] to continue again.
(8)Set the second print of the coarse adjustment

pattern on the scanner, making sure that the
chart is positioned correctly on the scanner.
Then click [Next].
* The print head angle adjustment printout will be
printed.
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HC50 00 20 05/12 (R ev. 3.0 )
(9)The print head angle adjustment printout

gives the information on which print head
needs to be adjusted in its mounting angle to
give good printout image. The adjustment
start from item (12) below.
* 0.1 = 45 degrees turn of the head angle jig.
* 1.0 = 360 degrees turn of the head angle jig (1 rota-
tion of the head angle jig.)
* Heads with 0.7 or less require no adjustment.
* The direction for the rotation of the head angle jig is
given on the printout. The red-color instructs to turn
the jig in counter-clockwise direction. The blue-color
instructs to rotate the jig in clockwise direction.
* The six print heads for each color is in numbered
from the rear of the machine. H1 is the print head at
the most rear of the machine. Then H2, H3, H4, H5
and H6 is the print head at the most front (operating
side) of the machine.
(10)Press [Next].
(11)Using [Safely Remove Hardware] on the

PC, disconnect HC5000 from the PC, and turn
of the HC5000 power by first pressing the soft-
switch and then shut the main power switch
OFF. Keep the PC power ON.
* If the heads do not require to be adjusted in their
angle, press [Next] and jump to the step (20).
(12)Referring to the section on the print head

removal, access to the mounting screws of the
print head.
Print head mounting screws
(13)Loosen the two mounting screws com-

pletely from the head to be adjusted.
Adjustment screw
(14)Rotate the head adjustment screw using the
head angle jig in the amount instructed on the
print head angle adjustment printout.
Do not loosen this screw

* The photograph shows the print head angle being

adjusted
* After adjusting the angle of each head, tighten the

two mounting screws on the print heads before
going onto the next print head to adjust. Torque
screw driver should be used to tighten these
print head mounting screws to the specified
torque power. Refer to the section on the print
head removal for the details.
Sample image
of the torque
driver.
Adjustment screw
being rotated by the
head angle jig.
* The top of the machine can be left opened until the

image adjustment is completely finished.
* Make sure to keep the duplex unit detached from
One of the two mounting the machine to prevent damaging of the print head
The screw which should
screws to be loosened ribbon cables.
never be loosened.
completely.
(15)Turn the HC5000 power ON and wait until
the machine status becomes [Ready]. If
the print mode is OFF, press the green Start
button to change the display message to
[Ready] status.
(16)The adjustment continues from the display

on the PC shown on the left.
(17)Do the Normal cleaning on the machine

once, and then click [Back] button 3 times to
return to the step [2/13 Rough Adj.], and
repeat the procedure given on the PC dis-
Go back 3 steps play. The print head angle adjustment
sheet will be printed out again.
* Though the print head angles are adjusted, as
instructed by the previous sheet, the newly printed
After going through the instructions step-by-step, the sheet may have the numbers over 0.7
print head angle adjustment sheet is printed out
* Unless the number is huge (such that the head
again, and the PC will display the message below.
angle jig was rotated the wrong way, etc.) there is no
need to re-adjust the print head angle again.
(18)Press [Next].
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HC50 00 20 05/12 (R ev. 3.0 )
(19)Follow the instruction on the new display.

Since the Normal head cleaning was already
The line should read as “Set the printer On-line”. done by the procedure (18), making sure that
the printer is On-line ([Ready] is displayed], click
[print].
(20)After following 4 Density Adj. Pattern copies

are printed, press [Next].
(21)Click [Next] and scan the 4 Density Adj. Pat-

terns in the order instructed by the new displays.
(22)After the 4 Density Adj. Patterns are

scanned, new instruction display will be shown,
asking to input the number of adjustments. The
default input number is 7. Click [Print].
(23)Seven sheets of Fine Adj. Pattern and one

Margin Adj. Pattern are printed. Press [Next].
7 copies of the Fine

Adj. Pattern are
printed.
One copy of Margin

Adj. Pattern is
printed.

(24)Measure the Top Margin, and Left and Right

Margin. Input the measurements to the 10th
of millimeter. Click [Next].
Top Margin
Left Margin Right Margin
Left Margin
Right Margin
Top Margin
(25)Following the instruction on the newly dis-

played instructions, scan the 7 Fine Adj. Pat-
terns printed by the previous step.
(26)Place A3 size Matte (coated) paper on the

standard paper feed tray. Press [Print].
(27)Overlap Adj. Pattern is printed out.
(28)If adjustment on the overlap is required,

press [Adjustment] and make adjustments
on the new display. If no adjustment is
Make either selection according to the print result required, press [Skip].
of the Overlap Adj. Pattern.
(29)Place A4 size paper horizontally on the

standard paper feed tray. Click [Print].
3 copies of Print Position Adj. Pattern sheets are

printed.
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HC50 00 20 05/12 (R ev. 3.0 )
(30)Click [Next] after 3 sheets are printed.
(31)Using the 2nd sheet, measure the length of

one of the two center lines. If center two
lines are erased on the ends, use one of the
outer 2 lines. Also measure the end mar-
gin (white margin).
Length
White margin
(32)Input the measurements to the 10th of milli-

meter.
Input the measurements.
(33)Click [Next].
* BY clicking [Next], the newly set parameters are
automatically saved in the NVRAM on the ORIP PCB.
(34)The display shown on the right will be

shown, and this completes the auto image
adjustment.
Do not perform this Test Mode menu yet. * The new display instructs you to activate Test
Mode [8.5.6.1 Save Adj. Config.], but do not acti-
vate this test mode at this time. This will be done
later.
(35)Go into menu [5.8.1. Sleep mode] and

change its setting back to the original set-
ting. This can be done now or later.
(36)Go into menu [4.10 Image area] and change

its setting back to the original setting. This
can be done now or later.
(37)Click [Exit] to close the above display.
(38)Click [Exit] again to close the image adjust-

ment software.
- continues on next page -

(39) Place A3 Matte (coated) paper on the standard paper feed tray
(40) With the PC still connected to HC5000 by the USB 2.0 cable, startup the OR_PRINT software,
which is included with the other image adjustment software in CD-R, etc.
(41) When following window is displayed, click the top [Ref.] button. Ignore the second [Ref.] button.
(42) After clicking the [Ref.] button, select “SE_PatternA3_2A” from the sample folder containing
many test image patterns.
(43) Keeping the rest of the setting on the display in the default condition unless wanting to change
the paper source tray, etc., click [Print].
* If more than one copy is needed, input the required number in the Print parameter sending box before
clicking [Print].
(44) After following test pattern is printed, use a loupe to magnify the print and check the result.
* If the test pattern printout is satisfactory, the auto image adjustment ended in good result.
Check the solid color area for the density and overlaps.
Check the horizontal and vertical lines.
Check the circles and the lines within.

The circles and the lines within the circles
should print out as composed black in color.
The image adjustment is very good if no other
colors are mixed in the circle images.
(45) If and only if the auto image adjustment made is satisfactory, select Test Mode [8.5.6.1. Save
Adj. Config.] to download the saved parameters in the NVRAM onto the ORIP PCB as backup
data.
(46) If the image adjustment made is not satisfactory, repeat the auto image adjustment from the
beginning.
* There is also a choice to return the image quality to that of before the image adjustment by activating Test
Mode [8.5.6.2 Restore Adj. Config.] to restore the original backup data from the ORIP PCB to the NVRAM,
if the original parameter setting was saved on ORIP PCB with [8.5.6.2 Restore Adj. Config.] before the auto
image adjustment was performed.
7 - 73
HC50 00 20 05/12 (R ev. 3.0 )
1-12. Exec utio n of Manual Image Ad justment
If the machine image quality is not as bad as to use the Auto Image Adjustment, but may still require
minor improvements. In these cases, Manual Image Adjustment, instead of the Auto Image Adjust-
ment, can be used. Though limited in the adjustments the Manual Image Adjustment, compared the
Automatic Image Adjustment, require much less time to perform.
Follow the steps given below to perform the Manual Image Adjustment.
(1) Place A3 size Matte (coated) paper on the standard paper feed tray.
(2) Connect the Laptop PC to HC5000 using USB 2.0 cable in the same way as for the Auto Image
Adjustment procedure.
* The USB drive for the HC5000 must also be downloaded in the PC, as it was for the Auto Image Adjust-
ment procedure, for the PC to recognize HC5000.
(3) From CD-R, etc., download the Manual Image Adjustment software [orTool Box] folder on PC
and double click [orToolbox_...._olytest.exe] Icon to start the software.
(4) Following window will be displayed.
(5) Above adjustment 1 is the X (horizontal) Position adjustment.

* This is equivalent to Test Mode [8.5.1.4 Horizontal offset].
(6) Above adjustment 2 is the Y (vertical) Position adjustment.
* This is equivalent to Test Mode [8.5.1.7 Vertical offset].
(7) Above adjustment 3 is the Print Head Overlap adjustment.
* This is equivalent to Test Mode [8.5.1.5 Horizontal overlap].
(8) Above adjustment 4 is the Print Head Density adjustment.
* This is equivalent to Test Mode [8.5.1.2 Voltage correction].
(9) Above 5 is the [Print] button to print the image to adjust.
(10) Above 6 is the [Adjust] button to jump to the adjustment display.
(11) Above 7 is the [Save] button to save the new parameter setting into PC.
* The parameter setting can be saved in the software folder in the PC for future recall of that setting. This
button is to save the parameter data into the PC. No need to use if not saving the data in PC.
(12) Above 8 is the [Load] button to save the new parameter setting into NVRAM on ORIP PCB.
* The past parameter setting can be downloaded into HC5000 by clicking this button and recalling the
parameter setting saved in PC during past adjustments (these past data exist only if they were saved in PC
during the past adjustments).
(13) Above 9 is the [Save] button to save the new parameter settings for 1 to 4 into PC all at once.
* Clicking this button after completing adjustments 1 through 4 will save the new parameter settings into
the PC. It is equivalent to clicking 7 for each adjustments 1 though 4 . Do only if needed.
(14) Above 10 is the [Load] button to save the new parameter settings for 1 to 4 into NVRAM on
ORIP PCB all at once.
* The past parameter settings can be downloaded into HC5000 by clicking this button and recalling the
parameter setting saved in PC during past adjustments (these past data exist only if they were saved in PC
during the past adjustments). It is equivalent to clicking 8 for each adjustments 1 though 4 . Do only if
needed.
(15) Above 11 is the [Sample Print] button to select and print test patterns included in the Manual
Image Adjustment software.
(16) Above 12 is the [Exit] button to exit from the Manual Image Adjustment software.

X (Horizontal) Position Adjustment
(1) Click [Print] button. The image shown below is printed out.
< Enlarged image from the print on the left >
If the setting is not good, the K/C, K/M and K/Y thin line does
not overlap one on top of the other, and gap (white line)
between the solid C, M, Y colors and solid black, or overlap
against the solid black color may appear. Looking at the thin
K/C, K/M and K/Y lines, make adjustments so each make one
line by landing on top of each other. K (black) is stationary.
(2) Click [Adjust] button to access to the dialog box screen.
(3) For each C, M, Y color for each print heads 1 through 6 (1 is on the drive side and 6 is on the
operator’s side of the machine), if the color has to move one dot to the right against the K, input
[+1]. Input [-1] if the color has to move one dot to the left of the K. Input the required number
for each box on the display.
(4) Click [OK] after desired numbers are filled in the boxes. Click [Cancel] to abort the adjustment.
* Clicking [OK] button will automatically load the new parameter setting into NVRAM on the ORIP PCB.
(5) After clicking the [OK] button above, the display returns back to the original display shown on the
previous page.
(6) Click [Print] button on the original display to make a new print to check the result of the adjust-
ment. If the result is not satisfactory, repeat the adjustment using the new printout as a guid-
ance.
(7) After the adjustment is completed, if wanted, click [Save] on the original display and save the
parameter setting in PC for future use. Omit this procedure if the data is not needed to be
saved in the PC.
(8) On the original display, if the [Load] button is clicked, past parameter data (if saved in PC) can
be selected and rewrite that parameter on HC5000 for the Horizontal position adjustment, if
wanted.
7 - 75
HC50 00 20 05/12 (R ev. 3.0 )
Y ( Ve r t i c a l ) P o s i t i o n A d j u s t m e n t
If the setting is not good, the K,

Enlarged image of the print on the right.
K/C, K/M and K/Y thin lines do
not print in overlapped straight
horizontal lines. In that case, the
solid block prints may overlap or
have gap (white line) running in
horizontal direction.
Using the adjustment display,
adjust the vertical print position
of each print head, 1 though 6,
so all the heads print at same
vertical position, making straight
lines across the paper. The left
is head No.1 and far right is
head No.6.
The best way to adjust is to
choose the 3rd or 4th head and
align the thin K color lines in one
horizontal line first. Then adjust
the C, M and Y color thin lines to
overlap with the K color line.
(3) Changing the parameter setting to larger number brings the print position down. Make the num-
ber smaller to raise the print position up.
previous page.
ance.
saved in the PC.
be selected and rewrite that parameter on HC5000 for the Vertical position adjustment, if
wanted.

Print Head Overlap Adjustment
If the adjustment is not good, the overlap

print area between the print heads (total 5
places per color) becomes too much or too
less.
If the overlap is too much the color at the
overlap becomes too dark.
If the overlap is not enough, white vertical
line will appear on the printout.
Adjust the overlap area referring to the

printout.
(3) Changing the parameter value to larger number will decrease the overlap. Making the number
small will increase the overlap.
previous page.
ance.
saved in the PC.
be selected and rewrite that parameter on HC5000 for the Print Head Overlap adjustment, if
wanted.
7 - 77
HC50 00 20 05/12 (R ev. 3.0 )
Print Head Density Adjustment
(1) Click [K], [C], [M] and [Y] buttons. The image shown below will be printed out. The one shown
below is of K color as an example.
If the adjustment is not good, the print

density across the image is not constant.
Looking at the printout, adjust the print
head which does not match with the
other print heads in the print density.
If there are more than one print head

which needs to be adjusted for a color, it
is very difficult to make the adjustment by
this Manual Image Adjustment software.
In those cases, it is recommended that
Auto Image Adjustment software is used.
(3) Changing the parameter value to larger number will increase the darkness. Make the number
smaller to decrease the darkness.
previous page.
(6) Click [K], [C], [M] and [Y] buttons on the original display to make new prints to check the result of
the adjustment. If the result is not satisfactory, repeat the adjustment using the new printouts as
guidance.
saved in the PC.
be selected and rewrite that parameter on HC5000 for the Print Head Density adjustment, if
wanted.

C l o s i n g t h e M a n u a l I m a g e A d j u s t m e n t S o f t w a re
(1) Before ending the Manual Image Adjustment software by clicking the [Exit] button, click the
[Sample Print and select “SE_PatternA3_2A” from the sample test pattern folder containing
many test image patterns, and make print.
(2) Checking the printed out test pattern image confirm that the image is good.
(3) If the print result of the test pattern print is not good, repeat the Manual Image Adjustment or if
judged not good enough to make the correction by the Manual Image Adjustment, do the Auto
Image Adjustment.
(4) To end the Manual Image Adjustment software, click the [Exit] button.
(5) After above display is closed, the new display shown below is displayed.
(6) The display instructs to perform Test Mode menu [8.5.6.1 Store Adj. Config.].
(7) Perform Test Mode [8.5.6.1 Store Adj. Config.] to download the backup data onto the PRIP PCB
if the Manual Adjustment went well.
(8) If the adjustment did not go well, do not perform Test Mode [8.5.6.1 Store Adj. Config.]
(9) Click [OK] to close above display.
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HC50 00 20 05/12 (R ev. 3.0 )
2 . A d j u s t m e n ts o n t h e C l e a n i n g U n i t .
This adjustment may become necessary if the cleaning heads on the cleaning unit are not cleaning
the print heads correctly due to incorrect parameter settings of the cleaning head positions during the
print head cleaning.
Make visual check of the present distances by operating Normal Cleaning.
If the distances are out of the setting as specified on the sketch below, that could be the cause for the
improper head cleaning. In that case, make the required adjustment.
* There are total of three adjustments.
(1) The three adjustments should be made in one set, in the given order.
(2) After all three adjustments are completed, activate SE-Mode [8.5.6.1 Store Adj. Config.] to copy
the new parameter settings saved in the NVRAM onto the ORIP PCB as backup data.
2-1.Clea ning start p ositi on

Refer to the following sketch and make an adjustment.
(1) Remove the center inner cover and plug two connector jigs into the connector plug.
(2) Turn ON the machine power.
(3) Activate SE-Mode and select [8.6.2 Nozzle Suck Pos.] and input the parameter setting of
13.0mm and enter.
(4) Activate 5.5.3 (Normal Cleaning), and while standing on the operators side of the machine,
watch and confirm that the most front rubber Wiper Blade is 0.5mm to 1.0mm away from the
Print Head for each color (K,C,M,Y) when the cleaning starts.
(5) If the measurement is not within 0.5mm to 1.0mm, change the setting on SE Mode No.8.6.2
* Increasing the parameter setting by SE-Mode No.8.6.2 decreases the distance, and decreasing the param-
eter setting increases the distance.
* If the wiper blade is too much away (too much space), the cleaning head will miss the print head
when the cleaning unit is raised. If that happens, the cleaning head will break off from the cleaning
unit when the leading edge of the cleaning head hits the print head at the start of the cleaning action.
This will damage both the cleaning unit and print head.

2-2. Cle aning posi tion
Refer to the following photograph and make an adjustment.
1.0 mm
The photograph shows the cleaning head before

touching the print head, so 1.0mm space cannot be Plastic bracket
seen. But when the cleaning head touches the
print head for the cleaning action, there should be
1.0mm space.
Plastic shaft on the cleaning head
(2) Activate SE-Mode and select [8.6.5 Cleaning Position] and make the parameter setting to
0.5mm and enter.
(3) Activate 5.5.3 (Normal Cleaning), and while standing on the operator’s side of the machine,
watch and confirm that during the head cleaning action, the space between the plastic bracket
and the shaft of the cleaning head is about 1.0mm.
(4) If the measurement is not approximately 1.0mm, change the setting on SE Mode No.8.6.5
* Increasing the parameter setting by SE-Mode No.8.6.5 increases the space, and decreasing the parameter
setting decreases the space.
* If the space is too little, the wiper blade will not wipe the ink off the print head nozzle surface properly
and causes misfires or cause ink blot to appear on the prints.
* If the space is too much, the cleaning head is pushing against the print head too strong and may
damage the print head. The cleaning head may break off from the cleaning unit.
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HC50 00 20 05/12 (R ev. 3.0 )
2-3.Clea ning fini sh po siti on
Refer to the following sketch and make an adjustment.
(1) The first two adjustments on the cleaning unit, described on the previous two pages, must be
completed before doing this adjustment.
(3) Turn ON the machine power.
(4) Activate SE-Mode and select [8.6.3 Nozzle End Pos.] and input the parameter setting of
86.0mm and enter.
(5) Activate 5.5.3 (Normal Cleaning), and while standing on the operators side of the machine,
watch and confirm that the rubber Wiper Blade is about 1.0mm away from the Print Head for
each color (K,C,M,Y) when the cleaning movement finishes.
(6) If the measurement is not about 1.0mm, change the setting on SE Mode No.8.6.3
* Increasing the parameter setting by SE-Mode No.8.6.3 increases the distance, and decreasing the param-
eter setting decreases the distance.

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HC50 00 20 05/12 (R ev. 3.0 )

Tro u b l e s h o ot i ng
CHAPTER 8: Tr oubleshooting
CONTENTS
8-1
HC50 00 20 05/12 (R ev. 3.0 )
Tr oubleshooting for printing problems
1.Causes of main printing problems and corrective mea-

sures
1-1.Procedure for res pondi ng to printing pro blems

(1) Check that the SE mode settings, mechanical settings and printer driver settings match with the
media which causes the error.
(2) Check whether the operating condition is within the specification.
(3) Activate SE mode, select the test pattern and printing mode necessary to examine the problem,
and output the test pattern.
(4) If necessary, output the user data and other test charts brought with you.
(5) Take corrective measures by referring to the following troubleshooting chart.
(6) Refer to the contents of the technical manual for troubleshooting the misfire (MF).
Image problem Cause Corrective measure

Printing fails, large non- • Print head tubes are bent, prevent- • Correct the bent tubes.
printed area ing supply of ink.
• Head joint (sealing valve) is closed, • Open the ink valve (sealing valve).
preventing supply of ink.
• There is a problem in the print • Replace the print heads.
heads.
• Three is a problem in the Head • Check and correct the connections for all
driver PCB or ORIP PCB. connectors of the PCBs indicated to the
left.
• Replace the PCBs indicated to the left.
• Defective vacuum operation due to • Correct the disconnected or bent tube of
disconnected suction tube (head the suction pump or suction chamber.
maintenance not possible)
• Ink problems • Replace the ink if it appears defective.
• Since degraded ink remaining in the ink
passages may cause problems, replace
the main ink passage components, if nec-
essary.
• Defective Controller(PS7R) • Correct the Controller(PS7R) problem.
White streaks • The print heads do not eject ink cor- • If the problem is due to misfire/non-per-
rectly. pendicular ejection, perform a normal
• Infrequently generated white streaks cleaning.
that can be eliminated by head • If the normal cleaning does not correct the
maintenance is regarded as part of problem, select the misfiring color, and
normal machine operations. It is not perform a thorough cleaning.
possible to completely eliminate in • Clean the ejection nozzles using a wipe
the inkjet system. stick.
• Replace the print heads.
• The conditions of the operating envi- • Confirm that room temperature and
ronment are unsuitable. humidity are within the permissible
ranges.
10 to 30 degrees Celsius 40% to 70% RH
essary.

The printed color is too • Paper with low ink absorption is • Use the appropriate media/print mode.
dark, or the ink runs. used in a print mode involving a
large number of drops.ÇÈ
• Prints are made on the wrong side of • Set the paper correctly.
the paper, due to incorrectly set
paper (especially when using coated
paper).
• The paper being used is unsuitable. • Use the appropriate media/print mode.
• The print density setting is too high. • Reduce print density.
essary.
The color is too light or • The paper being used is unsuitable. • Use the appropriate media/print mode.
uneven. • The conditions of the operating envi- • Confirm that room temperature and
ronment are unsuitable. humidity are within the permissible
ranges.
10 to 30 degrees Celsius 40% to 70% RH
• Paper (such as coated paper) with a • Set the print mode suitable for the type of
high ink absorption rate is used in a paper in use.
print mode that produces a small
number of drops.
• The print density setting is too low. • Increase print density.
essary.
Vertical lines are not • Incorrect adjustment Perform image adjustment.
straight. (For more information, refer to section 2 in
this chapter.)
• Transfer belt skew • Adjust the belt tension.
• Replace the transfer belt.
• Replace the transfer unit.
• Machine alignment is slightly dis- • Adjust the adjustment screw on the front
torted due to an uneven installation side.
surface. • Set up the machine on a flat surface, and
perform image adjustment if necessary.
Horizontal lines are not • Incorrect adjustment • Perform image adjustment.
straight. • (For more information, refer to section 2 in
this chapter.)
• Defective belt encoder (located • Correct installation conditions for the belt
inside the transfer belt unit) encoder.
• Replace the belt encoder.
Printing irregularities • Incorrect adjustment • Perform image adjustment.
• (For more information, refer to section 2 in
this chapter.)
• Analog ink remains in the ink pas- • Perform a thorough cleaning.
sage. • Replace the reservoirs.
• Replace the ID units.
essary.
8-3
HC50 00 20 05/12 (R ev. 3.0 )
Color mismatching/abnor- • Printing results differ from the colors • Due to differences between the RGB and
malities displayed on the monitor. CMYK color systems, printed colors may
not be identical to the colors displayed on
the monitor. Adjust the application and
RIP settings to achieve optimum color
matching.
• Analog ink remains in the ink pas- • Perform a thorough cleaning.
sage. • Replace the reservoirs.
• Replace the ID units.
essary.
Contaminated printed sur- • Contaminated paper transport path • Contaminated registration rollers Clean
faces (in single-side print- for single-side printing. • Contaminated cleaning roller (periodic
ing) replacement after 250,000 prints) -

2.Explanation of automatic image adjustment and adjusted
image quality
2-1. Overv iew of auto matic image adju stmen t

Automatic image adjustment for the printer involves scanning of the test pattern printed by the printer
using the image adjustment software and a scanner, and adjustment of parameters based on the
results of automatic measurement of the images. Through this process, the printer determines and
sets the optimum parameters automatically.
Of the image adjustment items, only the head angles need to be set manually. Except for the follow-
ing two items, image adjustment items are automatically set by the printer by exchange of information
with the image adjustment software.
When print heads are replaced during maintenance, the parameters for the recommended head drive
voltage and head drive AL must be changed before head angle adjustment. These two items must be
set manually on the Control panel and saved.
* For information on the image adjustment method, refer to [Adjustment after print head replacement] in [Ink
supply passages].
2-2. Overv iew of test patt erns fo r i m age adjustment

Use the following test patterns for automatic measurement and setting of parameters.
(1) Scanner calibration test chart

• Compensating for geometrical distortion of the scanner
(2) Coarse adjustment pattern

• Head angle parameter
• Print timing of two heads in each print head
(3) Density adjustment pattern

• Recommended drive voltage correction
(4) Fine adjustment pattern

• Print timing of print head
• Overlap amount
• Top edge registration
• Execution of fine adjustment of relative positions of colors and other settings
2-3. Parameters and image quali ty

Described below are the characteristics of image affected by parameter settings. If the image defects
described in a later section appear, the parameter settings may be unsuitable for the printer condi-
tions. If so, repeating automatic image adjustment will correct the problem. The original device condi-
tions will tend to drift over time, and automatic image adjustment may need to be repeated.
If the characteristics of the actual image differs from those described, image quality will not improve
even if automatic adjustment is performed. This is because such defective image conditions arise
from the mechanical instability of the paper transport system or other factors rather than parameter
settings. In these cases, you must locate and correct the cause of the problem.
8-5
HC50 00 20 05/12 (R ev. 3.0 )
Image defects caused by defective parameter settings are characterized by uniform deviation of dots.
On the other hand, mechanical defects result in irregular and uneven deviations. The occurrence of
the defect will also be unpredictable.
2-4.I mage defec ts ca used b y erro neous image adju stmen t perfo rmed by
service personn el
< H e a d d ri v e p a r a m e t e r 1 >
Paper transport direction
Applicable print head width
1) Voltage: After replacing a print head, enter the recommended drive voltage printed on the
new print head. If this recommended parameter value is not entered, image defects may
occur due to incorrect drive parameters (menus [8.5.1.1], [8.5.1.3]).
2) Characteristic of image defects: Image defects appear as a continuous difference in lateral

print head density. See the above diagram.
3) Corrective measure: Check the voltage value and AL type settings on the Control panel
(service mode) to see if they correspond to the values indicated on the label. If not, enter
the correct values according to the procedure described in [Adjustment after print head
replacement, 1-1Parameter setting]. Then perform image adjustment.
* Changing voltage values affects print timing. Be sure to perform image adjustment and to correct
other parameters.

< Head drive parameter 2 >
Paper transport direction Paper transport direction
Applicable print head width Applicable print head width
1) AL type: After replacing a print head, enter the recommended head drive AL type printed
on the new print head. If this recommended parameter value is not entered, image defects
may occur due to an incorrect defective drive parameter. (8.5.1.3)
2) Characteristic of image defects: When the printed image is positioned so that the paper
transport direction is vertical, as wide as the print head (see the left diagram), continuous
vertical print density differences are visible or misfires are seen due to ink ejection prob-
lems for the replaced head (see the right diagram).
3) Corrective measure: Check the AL type setting in the service mode on the Control panel to
see if it corresponds to the type indicated on the label. If not, enter the correct type accord-
ing to the procedure described in [Adjustment after print head replacement, 1-1Parameter
setting]. Then perform image adjustment.
* Changes in the AL type will affect print timing. Be sure to perform image adjustment and correct other
parameters.
8-7
HC50 00 20 05/12 (R ev. 3.0 )
< Defective head angle adjustment >
1) Head angle adjustment: After replacing a head, perform head angle adjustment.Refer to
[Adjustment after print head replacement, 1-5 Execution of image adjustment]. If this man-
ual setting of the head angle is performed incorrectly, image defects may arise.
2) Characteristic of image defects due to defective head angle adjustment 1. Deviation of

horizontal single-color lines
Deviation of horizontal single-

color lines
Example of defective printing

caused by misaligned K head
When the printed image is positioned so that the paper transport direction is vertical, the
defect appears in the horizontal lines of a single color. An abnormality is seen in horizontal
lines of a single color of K, C, M, or Y printed by the defective head. The horizontal lines of
a single color printed by the misaligned head are slightly displaced. If there is more than
one misaligned head, the horizontal lines of a single color will appear irregular. This defect
is produced continuously from the top of the page to the bottom. This defect appears in
every print. See the above diagram.
3) Characteristic of image defects due to defective head angle adjustment 2. Deviation of

horizontal multiple-color lines
Deviation of horizontal multi-

ple-color lines
Example of defective printing

caused by misaligned K head
When the printed image is positioned so that the paper transport direction is vertical, the
defect appears in horizontal multiple-color lines. Multicolor horizontal lines show a color
shift within the width of the misaligned head. This defect is produced continuously from the

top of the page to the bottom within the width of the applicable head. In some images, the
defect appears cyclically. This defect appears in every print. See the above diagram.
4) Corrective measure: Perform image adjustment, referring to [Adjustment after print head
replacement, 1-5 Execution of image adjustment].
2-5. Effects of para meters an d ima ge ch arac teristic s

Described below are image characteristics and the parameters that affect them. Note that defects
caused by parameters tend to generate uniform symptoms (such as constant deviations).
In the case of deviation of vertical multiple-color lines, for example, if the amounts of K and C devia-
tions are uniform from the top to the bottom, the defect is due to improper parameters. This defect
can be corrected by repeating image adjustment.
If the extent of the deviation gradually increases farther down the printed page, the defect is most
likely due to a paper transport problem such as paper skew. If so, remove the cause of the paper
skew.
< P r i n t d e n s i t y d i f f e r e n c e s a mo n g s i n g l e - c o l o r h e a d s
• Characteristics
Differences in print density with the adjacent head occurs within the head width. The den-
sity difference is continuous in the paper transport direction within the width of the print
head.
• Parameters that may lead to this problem

• The recommended drive voltage (Voltage) entered is incorrect or inappropriate.
• The recommended AL type entered is incorrect or inappropriate.
• Corrective measure
• Check the recommended drive voltage (Voltage) on the Control panel and correct the set-
ting.
• Check the recommended AL type on the Control panel and correct the setting.
8-9
HC50 00 20 05/12 (R ev. 3.0 )
• Perform image adjustment, referring to [Adjustment after print head replacement, 1-5 Exe-
cution of image adjustment].
• Replace the defective print head (determine the defective print head by checking the color
and position).
< F r e qu e n t m i s f i r e s o f c e r t a i n p ri n t h e a d s
• Characteristics
Certain print heads cause frequent misfires.
• Parameters that may lead to this problem

The recommended AL type entered is incorrect or inappropriate.
The print head is incorrect.
• Corrective measure
• Check the recommended AL type on the Control panel and correct the setting.
• Perform image adjustment, referring to [Adjustment after print head replacement, 1-5 Exe-
cution of image adjustment].
• Replace the defective print head (determine the defective print head by checking the color
and position).

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DANKA AUSTRALIA PTY. LTD.

Copyright: 2005 Riso Kagaku Corporation

RISO INTERNATIONAL GROUP

RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)

First paper feed section

Multi-tray paper feed section

Second paper feed section

Ink supply passages

Paper receiving section

Controller & power supply unit

Electrical Parts List

PCBs and Schematic diagrams

CHAPTER 1: Maintenance Notes

[ Handling of Lithium Battery ]

1. Never let the battery short-circuited.

[ Replacement of the Lithium Battery ]

1) The lithium battery must be replaced by a trained and authorized service

1-2 RISO KAGAKU CORPORATION -Technical Training Center-

Important Safety Precautions

2) Protection of the machine:

(3) Always connect electrical connectors firmly.

1) To avoid electrical failure:

2) Protection of the electrical components:

Wire harness connector

THEN Press the center, firmly.

1-1.Gen eral precautions

* Never perform maintenance while the machine is operating.

1-2.Speci al p reca ution s fo r c olor ink jet pri nters

1-4 RISO KAGAKU CORPORATION -Technical Training Center-

1-3. Other precautions for in specti on a nd mai nten ance

interrupt type (U-shaped) actuator type

1-6 RISO KAGAKU CORPORATION -Technical Training Center-

2-1. List of general tools

Type Size Shaft length, etc.

HEAD ANGLE JIG

Transfer unit support jig

Transfer belt stand jig

Interlock switch jig

• Jig 2 : Center photo (1 pc) - left hand door removed.

• Jig 3 & 4 : Bottom photo for - inner cover removed.

Printer unit lifting jig

1-8 RISO KAGAKU CORPORATION -Technical Training Center-

Image adjustment utility software:

Notebook PC (commercially available)

Flatbed scanner (commercially available)

USB 2.0 cables: 2 types of cables (commercially available)

Cleaning wipes (commercially available)

Gloves (commercially available)

Vacuum cleaner (commercially available)

Binder clip (commercially available)

IPA (isopropyl alcohol) or equivalent

A4-size coated paper

1 - 10 RISO KAGAKU CORPORATION -Technical Training Center-

Syringe of about 20 ml in size (commercially available)

2-3. Period ical Ma inten ance

Part Name Maintenance Interval Reference

3-1.Confirmatio ns to be pe rformed du rin g printer setup

1 - 12 RISO KAGAKU CORPORATION -Technical Training Center-

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1 - 16 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 18 RISO KAGAKU CORPORATION -Technical Training Center-

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