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Ricoh D124 Detailed Descriptions Manual

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D124
DETAILED
DESCRIPTIONS
MANUAL

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Summary of Contents for Ricoh D124

  • Page 1 D124 DETAILED DESCRIPTIONS MANUAL...

  • Page 3: Table Of Contents

    Maintenance Unit ..................6 Ink Supply ....................7 Waste Ink Collection................. 8 DRESS Sensor ..................9 1.1.5 SOME UNIQUE FEATURES OF D124 ..........10 Main Machine Stand and Scanner Stand ..........10 Front Cover Switches ................10 Ink Level Detection ................. 11 Cutter .....................
  • Page 4 4.2.2 ROLL FEED MECHANISM ..............66 4.2.3 INITIALIZING THE FIRST PAPER ROLL ........... 67 4.2.4 INITIALIZING THE SECOND PAPER ROLL ........71 4.2.5 ROLL REWINDING FOR REMOVAL..........72 From the registration standby position: ..........72 From the paper standby position: ............73 D124 Detailed Descriptions...
  • Page 5 K1 Print Head Uncapping/Capping............123 K2, C, YM Print Head Uncapping/Capping ........... 124 6.8.3 PRINT HEAD CLEANING CYCLE ............ 126 Step 2: Raising the Suction Cap ............127 Step 3: Suction ..................128 Step 4: Scraping and Wiping ..............129 Detailed Descriptions D124...
  • Page 6 8.1.2 OPERATION PANEL BOARDS (INSIDE OPERATION PANEL) ..159 8.1.3 STANDARD BOARDS (REAR) ............160 8.1.4 OPTION BOARDS (REAR) ............... 161 8.1.5 MCU, IPU ..................162 8.1.6 PSU ....................163 8.1.7 GW CONTROLLER BOARD ............164 8.2 DESCRIPTION OF ELECTRICAL COMPONENTS ........165 D124 Detailed Descriptions...

  • Page 7: Overview

    1. OVERVIEW 1.1 GENERAL This section is a quick summary of the external components of the D124. More details are provided in later sections of this document. 1.1.1 CONFIGURATION Six units comprise the machine. Unit Operation panel/Scanner unit Main unit...

  • Page 8: Features

    Roll feed. Two roll feed units (one standard, one option), and manual bypass feed are possible. A paper holding lever is provided on the right side of the machine allows loading cut sheets for copying and printing. Security. Standard HDD overwrite and encryption functions for security are provided. D124 Detailed Descriptions...

  • Page 9: Comparison To D093/D094

    1.1.3 COMPARISON TO D093/D094 The D124 is a wide-format inkjet printer that incorporates the design of the D093/D094 scanner unit. Here is a brief summary of the features of the D124 and D093/D094. D124 and D093/D094 Compared Item D124 D093/D094...

  • Page 10: Similarities With Previous Machines

    1.1.4 SIMILARITIES WITH PREVIOUS MACHINES The designs of the following components are nearly identical to those of earlier Ricoh inkjet printers. These features will be immediately recognizable to service technicians who are familiar with servicing the smaller inkjet copiers and printers.

  • Page 11: Vertical Paper Feed

     The vertical encoder HP sensor (7) stops the motor when the wheel reaches the home position at the end of a job. Detailed Descriptions D124...

  • Page 12: Maintenance Unit

     The maintenance lift motor (6) raises the three print head caps (K2, C, YM unit heads/caps) (7) that protect the print heads from drying out and slides the cleaning unit (8) forward and backward.  The maintenance lift motor and the sliding cleaning unit is a new mechanism. D124 Detailed Descriptions...

  • Page 13: Ink Supply

     An ink end sensor (9) and a small cylinder (10) with a floating impeller comprise the ink end mechanism. When ink runs out, the suction in the tube with no ink in it Detailed Descriptions D124...

  • Page 14: Waste Ink Collection

     A left ink sump (4) on the left side of the machine collects ink that is vented from the print heads occasionally during printing to prime the print heads and prevent them from clogging. D124 Detailed Descriptions...

  • Page 15: Dress Sensor

    DRESS sensor are used to adjust the timing of the piezo-electric elements in the print heads that release the ink. Timing is adjusted for the height of the carriage (and print heads), paper thickness, speed of the carriage, and print mode (uni-directional or bi-directional). Detailed Descriptions D124...

  • Page 16: Some Unique Features Of D124

    1.1.5 SOME UNIQUE FEATURES OF D124 Here is a summary of some new features. Main Machine Stand and Scanner Stand The scanner unit and main unit are mounted on separate stands. Front Cover Switches  The front cover (1) can be raised to remove paper jams and to load paper for bypass feeding.

  • Page 17: Ink Level Detection

    An OCFS (On Carriage Fill Sensor) system constantly monitors the ink level of each sub tank for each color. Cutter A one-direction cutter cuts roll paper from right to left and returns to the right side of the machine after cutting below the paper, without interfering with paper feed. Detailed Descriptions D124...

  • Page 18: Paper Feed Control

    (The number of rotations increases as the diameter of the paper roll decreases.) This pulse count is used in a calculation to determine how much paper remains on the roll. D124 Detailed Descriptions...

  • Page 19: Improved Productivity

    This increases printing speed because a wider band can be covered with one pass in a black-and-white print. During color printing [B], the K2 (3), C (4), and YM (5) print heads are used. The band is narrower because the forward sitting K1 print head is not used. Detailed Descriptions D124...

  • Page 20: General Layout

    1.2 GENERAL LAYOUT D124 Detailed Descriptions...
  • Page 21  The exit stacker (11) (Standard) is mounted on the front of the machine and requires installation. The exit stacker can be folded in when it is not being used (or for stacking outputs in a well-like structure) or extended for output of long sheets. Detailed Descriptions D124...

  • Page 22: Main Unit Layout

    Horizontal motor Timing belt Carriage unit Horizontal encoder sensor Horizontal encoder strip (semi-transparent) DRESS sensor Cutter motor Cutter Cutter return switch Cutter HP switch Maintenance unit Ink collector tank Right ink sump Left ink sump Vertical motor D124 Detailed Descriptions...
  • Page 23 This feature is controlled by the firmware and cannot be done by the operator. Paper Feed  The vertical motor (15) drives the registration roller and exit roller to feed paper in the vertical paper path and out of the machine. Detailed Descriptions D124...

  • Page 24: Motors, Clutches, Air Release Solenoid

    1.4 MOTORS, CLUTCHES, AIR RELEASE SOLENOID D124 Detailed Descriptions...
  • Page 25  The five ink pump motors (10) (one assigned to each print head sub tank inside the carriage unit) drive the pumps that supply ink to the print head units.  The cutter motor (11) drives the circular cutter from left to right during paper cutting. Detailed Descriptions D124...
  • Page 26 This prevents the print heads from abrading the surface of thick paper during printing. D124 Detailed Descriptions...

  • Page 27: Schematic Diagram

    Air release solenoid Main ink level sensor 2 (FS2) Main ink level sensor 1 (FS1) Ink supply pumps Ink end sensors Ink cartridges (K, C, M, Y) OCFS (On Carriage Fill Sensors) On carriage feelers Air sensors (pairs) Detailed Descriptions D124...

  • Page 28: Original Path, Paper Path Sensors

    1.6 ORIGINAL PATH, PAPER PATH SENSORS D124 Detailed Descriptions...
  • Page 29  The original exit sensor (4) detects when the trailing edge of the original exits the scanner unit to the upper exit (5) or rear exit (6). The original exits to the top with the original guide installed and exits to the rear with the original guide removed. Detailed Descriptions D124...
  • Page 30 Roll Unit 2 is at the registration standby position (17), the machine rewinds the paper to the second paper standby position 2 (19) if Roll Unit 1 or bypass feed is selected for a job. Both the paper standby positions are 51.5 mm away from the pre-registration sensor. D124 Detailed Descriptions...
  • Page 31  The carriage unit makes one pass over the paper so the DRESS sensor can detect the side edges of the paper and determine the width of the paper. This information is for image registration (the calculations to determine the starting point for printing the image). Detailed Descriptions D124...

  • Page 32: General Operation Sequence

     If the machine is accidentally unplugged from the wall power socket, or if a power outage occurs during the cleaning cycle after power on, the cycle will not resume from where it was interrupted after power is restored. You must do cleaning with the user tools after power is restored. D124 Detailed Descriptions...

  • Page 33: Scanning

    CIS unit, which is below the original path 6. The original is fed to the upper exit. If the original guide has been removed, the original feeds straight out the back of the machine. Detailed Descriptions D124...

  • Page 34: Paper Feed

    If Roll Unit 2 was selected for the job with paper from Roll Unit 1 at the registration standby position, the machine reverse feeds the paper down to the paper standby position below the pre-registration sensor, and then feeds paper from Roll Unit 2. 2. Paper feeds past the registration roller and stops. D124 Detailed Descriptions...
  • Page 35 6. The paper is reverse fed as far as the registration roller and stops. This is the registration standby position and the machine is ready to start printing. Detailed Descriptions D124...

  • Page 36: Printing

    2. During printing, the five feeler arms with actuators paired with OCFS (On Carriage Fill Sensors) constantly monitor the ink level of each sub tank above the print heads. D124 Detailed Descriptions...
  • Page 37  When an OCFS detects low ink, the machine will refill the sub tank. Detailed Descriptions D124...

  • Page 38: Cutting

    4. When the cutter reaches the left side of the machine, the cutter drops into a track below the paper, and then the cutter motor reverses and returns the cutter (passing below the paper) to its home position on the right side of the machine. D124 Detailed Descriptions...

  • Page 39: Paper Exit And Job End

    3. The paper transport fan switches off and the paper is reverse fed to the registration standby position. 4. The machine is ready for the next job. 5. If the machine remains idle for more than 14 min. (default), it will enter the Sleep Mode. Detailed Descriptions D124...

  • Page 40: Service Precautions

     Always hold the rollers by the bare ends where they are not coated.  Never use any type of strong organic solvent to clean the surface of these rollers. Use only a cloth very slightly dampened with alcohol or water to clean the rollers. D124 Detailed Descriptions...

  • Page 41: Permanent (Paint-Locked) Screws

    These screws are positioned and adjusted at the factory. Never loosen or attempt to adjust these screws. Right Plate Screws You can see the heads of four paint-locked screws around the top of the maintenance unit. These screws hold a re-enforcement plate. Never loosen or remove any of these screws. Detailed Descriptions D124...

  • Page 42: Maintenance Unit Base Screws

    There are also two paint-locked screws at the front. One screw at the front below the switch bracket [A] on the right. The other screw [B] is to the right of the temperature/humidity sensor above the ink supply unit. D124 Detailed Descriptions...

  • Page 43: Solenoid Bracket Screw

    The illustration above shows the left cover of the carriage unit removed. It is extremely important you never loosen or remove these screws. Tampering with these screws could cause the carriage unit to fall out of alignment or onto the platen plates. Detailed Descriptions D124...

  • Page 44: Platen Plate Guide Rod Screws

    Sensor and Temperature/Humidity Sensor Bracket This screw is paint locked. However, this bracket must be removed in order to remove the carriage unit. The bracket must be reinstalled at exactly the same position so the sensors are positioned correctly. D124 Detailed Descriptions...

  • Page 45: Pm Parts

    "PM Parts" because their service life will normally extend beyond the service life of the machine. Part Capacity Service Life Left ink sump 500 cc Approx 5 years or when tank full Right ink sump 147 cc Appox 5 years or when tank full Detailed Descriptions D124...

  • Page 46: Scanner Unit

    2. SCANNER UNIT 2.1 SCANNER LAYOUT 2.1.1 SIDE VIEW Item Original width sensors Original set sensor Original entrance roller Original registration sensor CIS unit Original exit sensor Original exit roller Scanner motor D124 Detailed Descriptions...
  • Page 47 This prevents the CIS unit from switching on while the cover is open.  Pressing the original stop key (a push-switch on the right side of the scanner unit) interrupts scanning if a problem occurs during scanning (wrinkling, skew) so that the original can be removed. Detailed Descriptions D124...

  • Page 48: Front View

    2.1.2 FRONT VIEW Item Safety switches Scanner motor Original set sensor Original registration sensor Original exit sensor CIS unit (5 elements) Original stop switch Original width sensors D124 Detailed Descriptions...

  • Page 49: Original Width Detection

     Inch. 11 sensors: 10 original width sensors and the original set sensor [1] which also functions as a width sensor. The NA machine has one additional width sensor [2] (30") . Detailed Descriptions D124...
  • Page 50  The sensors to the right of center (set sensor position "0") detect A series (Metric) or Engineering (USA) sizes.  If the original set sensor is the only one that detects paper, the machine detects an A4 or 8 ½" "A" size SEF original. D124 Detailed Descriptions...

  • Page 51: Scanning

     The original exit roller (7) feed the original out of the scanner unit while the scanned image is processed  The original stacker (8) and original guide (9) comprise the upper output tray (10). The upper output tray receives the original after scanning. Long originals will curl Detailed Descriptions D124...

  • Page 52: Auto Image Density Correction

     First, the CIS unit (1) reads the surface of the white strips (2) on the platen plate.  There is one white strip mounted above each section of the CIS unit. The machine uses these readings as reference points for density correction. D124 Detailed Descriptions...

  • Page 53: Scanning Area

    [B], and reads 60 mm to the left and to the right of center. These start positions can be adjusted with the following SP codes:  SP4901-005 Digital AE -Start Position  SP4901-006 Digital AE -Left Start Position  SP4901-007 Digital AE -Right Start Position Detailed Descriptions D124...

  • Page 54: Scan Magnification Correction

     Reducing the setting increases the speed of the scanner motor, and the image is reduced when it prints.  Increasing the setting reduces the speed of the scanner motor, and the image is enlarged when it is printed. D124 Detailed Descriptions...

  • Page 55: Original Drive Mechanism

    (3) and original exit roller (4).  The original set sensor (5) turns the motor on when the original is set.  The original exit sensor (6) switches the motor off when the sensor detects the trailing edge of the original. Detailed Descriptions D124...

  • Page 56: Original Feed Speed

     Black-and-white: When resolution is less than 300 dpi or less, or magnification is less than 50% [A]  Full color: When resolution is less than 400 dpi or less, or magnification is less than 66% [B] D124 Detailed Descriptions...

  • Page 57: Black-And-White Standard For Copying

     A copy reduced to 50% (one-half of an image at 100% 600 dpi) is reduced by removing half the pixels.  This is the same as a 300 dpi copy at 100%, in other words, the same as a document scanned to a file at 300 dpi. Detailed Descriptions D124...

  • Page 58: Scanning Mechanism

    This prevents the CIS unit from lighting up accidentally when the cover is open. The CIS unit is made of 5 contact image sensors connected at 4 joints. If you look from above, the CIS sections are numbered from left to right as CIS-1 to CIS-5. D124 Detailed Descriptions...

  • Page 59: Printed Image

    2.5.2 PRINTED IMAGE When you look at the copy to identify the areas scanned by each section, the numbering is in the opposite sequence, with CIS-5 on the left to CIS-1 on the right. Detailed Descriptions D124...

  • Page 60: Long Original Or Special Original With Carrier Sheet

    This prevents the original from falling on the floor. The trailing edge is held in the nip of the exit roller until it can be removed manually. This feature can be switched on/off with SP4975 (Prevent Original Falling). D124 Detailed Descriptions...

  • Page 61: Image Processing

    3. IMAGE PROCESSING 3.1 IMAGE FLOW 3.1.1 COPY JOB IMAGE DATA FLOW Detailed Descriptions D124...

  • Page 62: Scan Job Image Data Flow

    3.1.2 SCAN JOB IMAGE DATA FLOW 3.1.3 PRINT JOB IMAGE DATA FLOW D124 Detailed Descriptions...

  • Page 63: Copy Mode Image Processing

    The copy modes (selected from the operation on the main machine) are provided to achieve the best possible results in copying, depending on the type and quality of the original. Here is a brief summary of the copy modes as they appear in order of selection on the operation panel. Detailed Descriptions D124...
  • Page 64 Originals copied many times in succession with text letters starting to become distorted. Full color maps with fine lines. Highlight Pen Text marked with yellow highlight that you do not want to lose in a black-and-white copy. D124 Detailed Descriptions...

  • Page 65: Print Mode Image Processing

    CUD Print Adjusts colors so they are easily distinguished by those with color blindness. POP Optimization Best quality of outstanding colors for POP printing. Ink Save Best possible print production with less ink in order to conserve toner. Detailed Descriptions D124...

  • Page 66: Copy Resolution: Copy Jobs And Print Jobs

     Bi-Dir means "bi-directional" printing. The print heads lay down ink in two passes as the carriage unit moves from right to left and then right to left.  Switching. "Yes/No", the operator can/cannot switch between uni-directional and bi-directional printing. D124 Detailed Descriptions...

  • Page 67: Print Jobs

    600 x 1200 Quality Uni-Dir. 600 x 600 Coated/Color High Speed Uni-Dir. 600 x 600 Standard Uni-Dir. 600 x 1200 Quality Uni-Dir. 600 x 600 Special/Monochrome High Speed Uni-Dir. 600 x 600 Standard Uni-Dir. 600 x 1200 Detailed Descriptions D124...
  • Page 68  Bi-Dir means "bi-directional" printing. The print heads lay down ink in two passes as the carriage unit moves from right to left and then right to left.  Switching. "Yes/No", the operator can/cannot switch between uni-directional and bi-directional printing. D124 Detailed Descriptions...

  • Page 69: Image Troubleshooting

    Scanned + Grid Pattern A Scanned + Slant Grid A Grid Pattern B Scanned + Grid Pattern B Color Patch 16 Gradation Main Scan C Gradation Sub Scan C Slant Grid Pattern C Scanned + Grid Pattern C Detailed Descriptions D124...

  • Page 70: Paper Feed And Exit

    Encoder sensor 2 (paper) Registration roller Roll rewind switch Bypass sensor Spool Pre-registration sensor Paper exit guide Feed roller Paper exit guide switch Roll feeder exit sensor Exit sensor Paper release sensor Exit roller Roll feeder entrance sensor Cutter D124 Detailed Descriptions...

  • Page 71: Roll Unit Operation

     The vertical feed motor feeds the paper to the registration standby position below the registration roller [8].  The roll feed motor [4] reverse feeds with the clutch [7] off. This rotates the roll spool in reverse to take up slack. Detailed Descriptions D124...

  • Page 72: Roll Feed Mechanism

     When the roll paper feed motor rotates in reverse with the roll feed clutch ON, the feed roller rotates in reverse. The cam [4] also rotates, and this moves the idle roller [5] into and out of contact with the feed roller, so the paper reverse feeds intermittently. D124 Detailed Descriptions...

  • Page 73: Initializing The First Paper Roll

     The roll paper feed motor rotates the roll feed roller via the drive gears [4].  The paper continues to feed through the nip [1] of the roll feed roller and the idle rollers, which are still lifted into contact with the feed roller. Detailed Descriptions D124...
  • Page 74 [on the left side of the machine] turns on and rotates the registration roller [4] and exit roller [5].  When the DRESS sensor [6]detects the leading edge of the paper, the vertical motor stops. D124 Detailed Descriptions...
  • Page 75  When the motor turns in this direction, the cam shaft [3] rotates and moves the idle roller [4] down until the paper release sensor [5] turns on.  The feed roller and idle roller are now separated. Detailed Descriptions D124...
  • Page 76 [2], stops, and then reverses.  When the DRESS sensor [3] detects the edge of the paper again, it starts a count, and then stops the paper at the registration standby position [4] above the registration roller [5]. D124 Detailed Descriptions...

  • Page 77: Initializing The Second Paper Roll

     "Initializing the First Paper" [described above] is executed for the roll paper in Roll Unit 2.  The leading edge of the Roll Unit 2 paper stops at the registration standby position at the registration roller [4]. Detailed Descriptions D124...

  • Page 78: Roll Rewinding For Removal

    So the next time paper is inserted, the nip is already closed.  The operator then turns the roll by hand until the edge of the paper comes out of the machine. D124 Detailed Descriptions...

  • Page 79: From The Paper Standby Position

    So the next time paper is inserted, the nip is already closed.  The operator then turns the roll by hand until the edge of the paper comes out of the machine. Detailed Descriptions D124...

  • Page 80: Roll End

     The paper is pulled taut, up against the actuator of the roll end sensor (3). This signals roll end and switches off the vertical feed motor and horizontal motor. This shuts down paper feed and printing.  The machine displays a message to alert the operator that the roll needs replacement. D124 Detailed Descriptions...

  • Page 81: Main Unit Paper Feed

     The vertical motor (1), controlled by the vertical encoder wheel (2), vertical encoder sensor (3), and vertical encoder HP sensor (4), drives the timing belt (5) that rotates the registration roller (6) and the exit roller (7) Detailed Descriptions D124...

  • Page 82: Vertical Feed Mechanism

    4.3.2 VERTICAL FEED MECHANISM Item Paper holding lever cam Pressure arm Registration roller idle rollers Vertical motor Drive belt Registration roller Exit roller Vertical encoder sensor Vertical encoder wheel Vertical encoder HP sensor Exit sensor D124 Detailed Descriptions...
  • Page 83  The vertical encoder HP sensor (10) detects the small hole in the encoder wheel, and then stops the vertical motor with the wheel at the home (start) position.  The exit sensor (11) detects the leading edge and trailing edges of the paper as it leaves the machine. Detailed Descriptions D124...

  • Page 84: Remaining Paper Detection

    (The number of rotations increases as the diameter of the paper roll decreases.) This pulse count is used in a calculation to determine how much paper remains on the roll. D124 Detailed Descriptions...
  • Page 85  The encoder wheel and sensor, and a small PCB in the roll unit, comprise the device that measures the amount of paper remaining on the roll.  The residual paper detection encoder is a small wheel with 40 slits (spokes) around its center capable of generating 503 pulses with one rotation. Detailed Descriptions D124...

  • Page 86: 5-Step Operation Panel Display

    Less than 98 φ161 99 to 107 φ149 108 to 116 φ137 117 to 127 φ125 128 to 141 φ113 142 to 158 φ101 159 to 179 φ89 180 to 207 φ77 208 to 245 φ65 More than 246 D124 Detailed Descriptions...

  • Page 87: Paper Transport Fan

    Duty 1 mode. This pulls the paper down onto the perforated platen plates and keeps it perfectly flat for cutting and printing.  The fan remains on until the end of the job.  The fan duty is adjusted for each phase of this operation (see below. Detailed Descriptions D124...

  • Page 88: Transport Fan Duty Adjustment

     When the cutter (5) reaches the left side of the machine after cutting the paper, the cutter return switch switches on, and the cutter motor reverses to return the cutter to its home position on the right side of the machine. D124 Detailed Descriptions...
  • Page 89 The duty levels are set according to paper type, width and thickness for each type of paper:  Normal, recycled paper  Ink jet paper  Translucent paper  Coated paper  Matte film  Special paper Detailed Descriptions D124...

  • Page 90: Normal Paper, Recycled Paper

    Duty 2 Duty 3 279.4 to 420 420 to 620 620 to 841 841 or wider Normal Duty[%] Width: mm Duty 1 Duty 2 Duty 3 279.4 to 420 420 to 620 620 to 841 841 or wider D124 Detailed Descriptions...
  • Page 91 (the percentage to be added to the current operation level.)  It is important to remember that if an adjustment is done with this SP code for a particular paper type, it will be added to any change previously specified with SP1955-001. Detailed Descriptions D124...

  • Page 92: Detailed Description Of Paper Feed Sequence

    Paper entrance sensor Registration roller Paper feed roller Registration standby position Paper exit sensor DRESS sensor Paper standby position (RU 1) Paper leading edge Paper standby position (RU 2) Cutter Pre-registration sensor Exit roller Bypass sensor Exit sensor D124 Detailed Descriptions...

  • Page 93: Operation Sequence When The First Roll Is Set

    14. Horizontal Motor ON > carriage moves to the left and delays 1 sec. 15. Paper feed motor > ON at 35 mm/s and vertical motor > ON Fwd at 100 mm/s 16. Paper feeds 60 mm > paper feed motor OFF > Vertical motor OFF. Skew Correction Detailed Descriptions D124...

  • Page 94: Paper Skew Correction

    If the deviation is not within ±5 mm, the paper is released, the vertical motor and paper feed motors reverse feed, and the paper rewinds onto the roll. 27. The paper feed sequence continues from Step 18 of "Paper Feed Sequence When First Roll is Set" above. D124 Detailed Descriptions...
  • Page 95 30. The machine records the readings of the horizontal encoder for the right and left edges of the paper. This is done to confirm the paper size with the selection done with an external coin operated device if one is attached. Detailed Descriptions D124...
  • Page 96 38. Cutter return sensor switch ON > Cutter motor drives the cutter back to its home position on the right. 39. Paper feed motor > ON reverse feeds and stops. 40. Vertical motor > ON then stops when DRESS sensor detects the leading edge at the paper registration position. 41. END. D124 Detailed Descriptions...

  • Page 97: Operation Sequence When The Second Roll Is Set

    5. The roll unit clutch, paper feed motor, and paper release sensor go off and the paper stops. 6. The paper is now at the paper feed standby position 51.5 mm downstream of the pre-registration sensor, and the path is open for paper from the other roll to feed. Detailed Descriptions D124...

  • Page 98: Cutting

    5. The motor and drive belt pull the cutter back to the right. When the cutter reaches the cutter HP sensor (6), the sensor signals the machine to shut down the motor and the cutter stops at its home position. D124 Detailed Descriptions...

  • Page 99: Bypass Feed

    3. The operator raises the front cover, and then raises the paper holding lever on the right side of the machine. 4. The paper must be inserted with the right edge of the paper on the alignment mark [A] at the right end of the platen. Detailed Descriptions D124...
  • Page 100 Normally, the margin at the trailing edge is 18 mm, except when printing with color in the following cases: Media Print Mode Special Standard Special Quality Matte Film Quality Tracing Paper Quality D124 Detailed Descriptions...

  • Page 101: Ink Supply

    There are four short ink supply tubes (one for each cartridge) between the ink cartridge port and the pumps. The black tube splits into two supply tubes before the pumps, one for K1 and one for K2, bringing the total of tubes to 5. Detailed Descriptions D124...
  • Page 102 The sensor is above the actuator of the feeler attached to the side of the sub tank. This feeler and actuator monitors the level of ink in each sub tank and triggers an alert when ink runs low. D124 Detailed Descriptions...

  • Page 103: Ink Cartridge

    At the 5th level (35 to 20%):  When the ink level is between 35% and 20%, this signals pre-near end. The machine displays a message that alerts the operator to prepare a new ink Detailed Descriptions D124...
  • Page 104 The chip and CCB contact is also used to transfer the ink usage count from the main machine to the memory map of the chip. D124 Detailed Descriptions...

  • Page 105: Ink Supply Mechanism

     When the ink in a cartridge runs out, the ink pump motor continues to try to draw ink from the ink port. But with no ink, this creates a negative pressure between the pump and the ink cartridge. Detailed Descriptions D124...
  • Page 106  This action of the cam alternately applying and releasing pressure against the side of the tube drives the ink out of the pump and into the tube (6) to the carriage unit and print head sub tank above. D124 Detailed Descriptions...

  • Page 107: Controlling Ink Supply To The Sub Tanks

    OCFS [5] (On Carriage Fill Sensor).  The air sensors [6] are a pair of vertical terminals attached to the top of the ink sub tank. These sensors detect air in the tank. Detailed Descriptions D124...
  • Page 108  The actual level of the ink does not change at [2] and [3] even though there is less ink in the tank.  However, if air enters the tank [4], the air sensors at the top of the tank will be exposed and detect air in the tank. D124 Detailed Descriptions...

  • Page 109: Controlling Ink Supply During Printing

     Air is detected in a tank. (The purging and filling is not done until the end of the job.)  Before print head flushing  When the temperature/humidity sensor detects a change in humidity of more than  When the temperature/humidity sensor detects a change in humidity of more than Detailed Descriptions D124...

  • Page 110: Air Purge Mechanism

     As more ink flows into the tank, the actuator moves in direction of the red arrow toward the full position.  After air has been purged, ink is pumped from the cartridge up to the sub tank, and then 0.6 cc of ink is pumped out by reversing the ink pump. D124 Detailed Descriptions...

  • Page 111: After Air Purging

    Tank Full Position.  This sequence is also done at cleaning and flushing.  The carriage does not move to this sensor during printing. (Ink level during printing is checked with the OCFS sensors.) Detailed Descriptions D124...

  • Page 112: Printing

    This controls the operation of the motor and movement of the carriage unit during printing and other operations, such as paper registration and image registration.  The DRESS sensor (6) performs paper registration and image registration while the carriage unit is moving during paper feed. D124 Detailed Descriptions...

  • Page 113: Carriage Unit

    Horizontal encoder sensor DRESS sensor Horizontal encoder strip Ink level sensor 1 Print head thermistors Ink level sensor 2 HT1 (Head Tank K1) Temperature/humidity sensor HT2 (Head Tank K2) Head lift motor HT3 (Head Tank C) Head lift sensors Detailed Descriptions D124...
  • Page 114 While ink level sensor 1 services only the K1 print head unit, and ink level sensor 2 services the other four sub tanks.  The temperature/humidity sensor (17) constantly measures the temperature and D124 Detailed Descriptions...
  • Page 115 K2 overlap the same area on the paper. However, the arrangement of the nozzle ports is staggered so positions of the nozzle ports complement one another when ink is put down on the paper. Detailed Descriptions D124...

  • Page 116: Print Head Unit

    6.3 PRINT HEAD UNIT Item Head thermistor (Black) Head thermistor (Color) Air sensors pairs Purge valves Ink sub tanks (K1, K2, C, Y, M) Ink sub tank feelers Filter units Print head units (K1, K2, C, YM) Print heads D124 Detailed Descriptions...
  • Page 117  Note that he YM print head on the right has two tanks on the same print head,, but each tank has its own array of ink ports.  The print heads (9) eject the ink onto the paper.l Detailed Descriptions D124...

  • Page 118: Print Head

     The vibration plate (3) and flow plate (4) apply the ink evenly to the back of the nozzle array plate (5).  The ink flows evenly through the ports of the nozzle array plate. D124 Detailed Descriptions...

  • Page 119: Dress Sensor

     Skew correction. Checks and corrects skew at the right edge of the paper. If the edge is skewd more than ±10 mm, the machine rewinds the paper onto the roll. Detailed Descriptions D124...
  • Page 120 (uni-directional or b-directional). 1. When a job starts, the horizontal motor switches on and moves the carriage (1) across the paper so that the DRESS sensor (2) can detect the right and left edges of the paper. D124 Detailed Descriptions...
  • Page 121  A larger setting moves the image to create a wider left margin.  A smaller setting moves the image to the create narrow left margin. Image position adjustment in the main scan (horizontal) direction Margin (white space) Detailed Descriptions D124...

  • Page 122: Temperature Monitoring

     The adjustment is done by changing the duty (strength of electrical charge) used to activate the piezoelectric elements that project ink through the ink nozzles of the print heads. (The amount of ink ejected will vary directly with the amount of charge applied to the piezoelectric element.) D124 Detailed Descriptions...
  • Page 123 In this case, the machine does not require cycling off/on. The initial cleaning will start as soon as the machine has warmed up, and then the machine is ready for operation. Detailed Descriptions D124...

  • Page 124: Print Head Height Adjustment

    (1).  The head lift motor rotates the cam (2) and raises the carriage unit (3) with the cam pressing against the bottom of the carriage. D124 Detailed Descriptions...

  • Page 125: Raising And Lowering The Print Heads

    2. Touch [System Settings], touch [Next], and then touch [Prevent Paper Abrasion]. 3. The first selection is for a bypass print job. The second and third selections are for Roll Feed 1 and Roll Feed 2, respectively. Detailed Descriptions D124...
  • Page 126 This disengages the shaft and lift motor couplings.  The cam keeps the carriage and print heads raised until the operator does the procedure again to return them to the standard position. D124 Detailed Descriptions...
  • Page 127  The print heads can be capped with the carriage raised to the Weak and Strong positions.  However, bi-directional printing is not allowed with the print heads raised. The setting must be switched OFF (standard) to use bi-directional printing. Detailed Descriptions D124...

  • Page 128: Maintenance Unit

    Slide sensor Maintenance motor Suction pump Suction cap sensor Suction cap actuator Color print head caps (K2, C, YM) Lift lever (K2, C, YM) Carriage stopper Lift sensor Lift sensor actuator Lift motor Cap pads (K2, C, YM) D124 Detailed Descriptions...

  • Page 129: Capping/Uncapping

    K1 print head.  The rotating suction cap actuator (4) (mounted on a shaft with a lift cam driven by the maintenance motor) and suction cap sensor (5) control the raising and lowering of the suction cap. Detailed Descriptions D124...

  • Page 130: K2, C, Ym Print Head Uncapping/Capping

     The rotating lift actuator (4) (mounted on a shaft with a cam driven by the lift motor) and lift sensor (5) control the lowering of the three print caps.  The caps rest on the absorbent cap pads (6) while they are down. D124 Detailed Descriptions...
  • Page 131 (not shown) on the lift lever (3) and covers the print heads to prevent them from drying out.  The rotating lift actuator (4) (mounted on a shaft with a lift cam driven by the lift motor) and lift sensor (5) control the raising of the caps. Detailed Descriptions D124...

  • Page 132: Print Head Cleaning Cycle

    [A].  At the start of the cleaning cycle, the carriage unit (1) positions itself over the maintenance unit (2).  The lift motor (3) rotates in reverse and drives the gear train (4). D124 Detailed Descriptions...

  • Page 133: Step 2: Raising The Suction Cap

     The suction cap actuator (4) (attached to the shaft with the cam driven by the maintenance motor to raise the suction cap) and suction cap sensor (5) signal the machine to turn off the motor when the cap is up and sealed on the print head. Detailed Descriptions D124...

  • Page 134: Step 3: Suction

    (5) and continues down to the ink collector tank below the maintenance unit on the right side of the machine.  The suction cap lowers away from the print head after suctioning ink for the prescribed time. D124 Detailed Descriptions...

  • Page 135: Step 4: Scraping And Wiping

     Next, the linkage cocks the spring loaded wipers [4] to the rear, and then releases them so that they spring forward and flick any remaining ink into the vent. This is done twice. This completes the cleaning cycle. Detailed Descriptions D124...

  • Page 136: Manual Print Head Cleaning And Flushing

    These idle time counts are used to execute these operations:  Air purging (ink supply and purging, filling and cleaning, and air purging/filling together)  Ink supply sequence  Cleanings and flushing (refreshing) done by the operator manually  Ink purging done after idle time D124 Detailed Descriptions...

  • Page 137: Maintenance Cycles Based On Idle Time

     SP2514 Auto Cleaning Start Threshold.  SP2521-001 to -003 Maintenance After Leftover Repeat.  SP2517 Maintenance After Leftover Information.  SP2520 Maintenance After Leftover Setting On/Off Switch. For more details, please refer to the SP tables in the Appendices. Detailed Descriptions D124...

  • Page 138: Automatic Mist Cleaning

     Count adjustment. The count is automatically adjusted for the width of the paper and total print area.  Paper dust count. The paper dust count (the total number of pages printed, cutting count) are used to determine when cleaning is done for paper dust. D124 Detailed Descriptions...

  • Page 139: Waste Ink Collection

    (with a very small amount of ink) which falls into the left ink sump (5). This keeps the nozzles primed and in good working condition. This operation is controlled by the machine firmware and is not part of the print head cleaning cycle. Detailed Descriptions D124...

  • Page 140: Ink Collector Tank

    "end history" setting is written into the ID chip to prevent the tank from being used again. The tank near full and full thresholds that trigger the near-full and full alerts can be adjusted with SP2507-001, 002. D124 Detailed Descriptions...
  • Page 141  Tank full. A prompt appears on the operation panel of the machine. If a page is being printed, the job will finish, and then the machine will shut down and cannot be used until after the tank has been replaced. Adjusting SP2507-001 and 002 is not recommended. Detailed Descriptions D124...

  • Page 142: Right Ink Sump

    "0" with an SP2505-002. D124 Detailed Descriptions...

  • Page 143: Left Ink Sump

     Normally, purging is done in this order: Color heads H3 (C), H4 (YM) and then Black heads H1 (K1), H2 (K2) with no delay between color and black purging.  Purging may be slightly slower at cooler temperatures around 15°C (59°F) Detailed Descriptions D124...

  • Page 144: Print Head Cleaning And Adjustment

    7.1 MAINTENANCE MENU ADJUSTMENTS There are seven important adjustments on the Maintenance Menu that the service technician must be familiar with. 1. Press the button on the operation panel. 2. Touch [Maintenance] to open the Maintenance Menu. D124 Detailed Descriptions...
  • Page 145  Adjust Paper Feed. Do this procedure if you see broken horizontal lines, patchy images, or white lines at regular intervals in your printouts.  Adjust Print Position. Do this procedure to adjust the print start position at the upper left corner of each sheet where printing starts. Detailed Descriptions D124...

  • Page 146: Nozzle Check, Clean And Flush Print Heads

     The third selection will not display if Roll Unit 2 is not installed. 4. Select the paper feed station and then touch [OK]. A message will ask you to wait while the pattern is printing. 5. When the message prompts you that the pattern printing has completed, touch [Exit]. D124 Detailed Descriptions...
  • Page 147  If the print heads are operating normally, none of the lines are broken. Abnormal  If you see bare patches caused by broken lines, one or more print head need cleaning or flushing. 7. Go to the next section below to clean the print heads. Detailed Descriptions D124...

  • Page 148: Clean Print Heads

    If one or more ink tanks are empty, replace the ink cartridge, and then print another Nozzle Check Pattern. 2. Touch [Clean Print-heads].  There is one selection for each print head unit. D124 Detailed Descriptions...
  • Page 149 [Start]. A message will ask you to wait while the print heads are being cleaned.  Cleaning one print head takes about 60 sec.  The Magenta and Yellow print heads require about 120 sec. 4. When the message tells you that print head cleaning has completed, touch [Exit]. Detailed Descriptions D124...
  • Page 150 Print head flushing consumes a significant amount of ink. Never flush the print heads until three print head cleanings have failed to solve the problem. D124 Detailed Descriptions...

  • Page 151: Flush Print Heads

    Flushing a print head requires about 3 minutes. 3. When the message tells you that the flushing is completed, touch [Exit]. 4. The display will loop back to the Maintenance Menu. Touch [Print Nozzle Check Detailed Descriptions D124...

  • Page 152: When Printing Cannot Be Restored

    7. If the results are still not satisfactory, execute SP2100-003 (Special Maintenance – Fully Automated Cleaning). 8. Finally, if the problem has not been solved, replace the print head cradle where the defective print head is located. D124 Detailed Descriptions...

  • Page 153: Auto Adjust Head Position

    Adjust the print head position if you see these problems in the prints:  Broken vertical lines  Blurred or streaked colors 1. Press the button on the operation panel. 2. Touch [Maintenance]. 3. Touch [Auto Adjust Print Head Position]. Detailed Descriptions D124...
  • Page 154  A message will ask you to wait while the adjustment is done and a pattern prints.  If the adjustment succeeded, the pattern will look like the one above. The black arrow indicates the direction of paper feed. D124 Detailed Descriptions...
  • Page 155  If the automatic adjustment fails, a message will say "Failed to adjust" and tell you to do the adjustment manually. (See the next section below.) Detailed Descriptions D124...

  • Page 156: Manual Adjust Head Position

    3. Touch [Manual Adjust Head Position]. Target Location (Paper Source) Paper Bypass Location Bypass paper feed Paper Input Location 1 Roll Unit 1 Paper Input Location 2 Roll Unit 2 Resolution Speed Draft Standard Standard quality Quality High quality D124 Detailed Descriptions...
  • Page 157  A message will ask you to wait while the test pattern prints. 5. Look at the test pattern.  Identify the number of the column where the square is faintest.  Write down these values for reference (A4, B2, etc.) 6. Touch [Adjustment]. Detailed Descriptions D124...
  • Page 158 7. Enter the values for each row. (Just press the plus or minus button; the numbers will appear automatically.) 8. Print another test pattern, to make sure that the numbers you entered correspond to the results in the test pattern. D124 Detailed Descriptions...

  • Page 159: Adjust Paper Feed

    2. Touch [Maintenance]. 3. Touch [Adjust Paper Feed]. 4. Select [Print Test Pattern] for the paper feed source. Paper Bypass Location Bypass paper feed Paper Input Location 1 Roll Unit 1 Paper Input Location 2 Roll Unit 2 Detailed Descriptions D124...
  • Page 160 5. Touch [Start Printing]. 6. The adjustment value appears to the left of the lightest gray square with straight horizontal lines on both sides. 7. Touch [Adjustment]. D124 Detailed Descriptions...
  • Page 161 8. Touch the plus or minus key to enter the number where you identified the correct value in the test print. (Pressing either key increments/decrements the numbers automatically.) Detailed Descriptions D124...

  • Page 162: Adjust Print Position

    Paper Bypass Location Bypass paper feed Paper Input Location 1 Roll Unit 1 Paper Input Location 2 Roll Unit 2 5. Touch [Start Printing]. A message will ask you to wait while the test sheet is printing. D124 Detailed Descriptions...
  • Page 163 Increasing the value for the top and left margins moves the print position down and to the right. You will see the blue square move as you change the settings, so you can confirm the effect of the changes. Detailed Descriptions D124...

  • Page 164: Electrical Components

    SIB (Scanner Interface Board). Located at the left rear corner of the scanner unit, interfaces with the five CIS elements and corrects sub scanning. Image data scanned by the CIS elements is converted from analog to digital data by the SIB and then sent to the IPU for processing. D124 Detailed Descriptions...

  • Page 165: Operation Panel Boards (Inside Operation Panel)

    Also contains the LEDs for the left side keys.  OP-R. (Operation Panel-Right). Relays key presses from keys located on the right side of the panel. Also contains the LEDs for the right side keys. Detailed Descriptions D124...

  • Page 166: Standard Boards (Rear)

     Carriage unit (from the horizontal encoder strip)  Vertical motor (from the vertical encoder wheel)  Roll paper feed (from the encoder in the roll feed unit) D124 Detailed Descriptions...

  • Page 167: Option Boards (Rear)

    1 Wireless LAN Enables wireless communication. 2 File Format Converter Also called "MLB (Media Link Board)" 3 Roll Feed Unit 2 2nd Roll Unit (Option) 4 Copy Data Security Prohibits copying of currency and other restricted items. Detailed Descriptions D124...

  • Page 168: Mcu, Ipu

    The MCU also sends load signals and supplies power to:  Base engine (high voltage power pack, motors, sensors, solenoid, and clutch.)  Scanner (sensors, motors, etc.) The MCU DIP switches must always be OFF (default) and they must not be changed in the field. D124 Detailed Descriptions...

  • Page 169: Psu

    IPU (Image Processing Unit) The IPU (Image Processing Unit) processes image data from the CIS (Contact Image Sensors). 8.1.6 PSU The PSU (Power Supply Unit) supplies DC power for all electrical components in the machine. Detailed Descriptions D124...

  • Page 170: Gw Controller Board

    The controller board controls the memory and all peripheral devices. The GW architecture controls all applications, i.e. copying, printing, and scanning. The controller board has board slots and SD card slots that allow installation of the controller options. D124 Detailed Descriptions...

  • Page 171: Description Of Electrical Components

    K2 sub tank in the K2 print head unit. Ink Pump Motor (K1) Pumps black ink from the Black print cartridge in the ink supply unit to the K1 sub tank in the K1 print head unit. Detailed Descriptions D124...
  • Page 172 When the max limit count Is exceeded, this signals tank full, and the machine disables the code so that the tank can no longer be used. D124 Detailed Descriptions...
  • Page 173 Detects when the paper roll in Roll Unit 2 runs out of paper. Encoder Sensor 2: RU2 Monitors rotation of the outer circumference of the paper roll in Roll Unit 2. This count is used in a calculation to determine the amount of paper remaining on the roll. Detailed Descriptions D124...
  • Page 174 Located at the top of the vertical paper feed path in the main unit, detects the leading edge of the roll. Original Width Sensor: B4 Detects B4 width paper. Original Width Sensor: B3 Detects B3 width paper. Original Width Sensor: B2 Detects B2 width paper. D124 Detailed Descriptions...
  • Page 175 On Carriage Fill Sensor Y. The on-carriage sensor that monitors the position of the feeler arm on the side of the Y ink sub tank. This sensor is used to signal low ink in the Y sub tank. Detailed Descriptions D124...
  • Page 176 This ensures that the carriage unit is at rest on the right side of the machine with the print heads capped. (This causes a slight delay and a 2 minute warning when the main power is switched off.) D124 Detailed Descriptions...
  • Page 177 Print Head (K1) Print head for the Black (K1) print head unit. Other Print Head (K2) Print head for the Black (K2) print head unit. Other Print Head (YM) Print head for the Yellow/Magenta (YM) print head unit. Detailed Descriptions D124...

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