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Ricoh Be-C2 Technical Training Manual

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This course explains how to service the Be-C2 series of wide-format black-
and-white copiers.
These machines are successors to the Be-C1 and Be-C1.5 series.
The machine is very similar to the older models. However, there are some
differences. The important ones are mentioned in this course. Also, see
Guidance for Those Familiar with Predecessor Products in the field service
manual, where all the differences are described in one section.
30 January: Slide 37 was corrected, and a new slide was added after this
slide.
1

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Summary of Contents for Ricoh Be-C2

  • Page 1 This course explains how to service the Be-C2 series of wide-format black- and-white copiers. These machines are successors to the Be-C1 and Be-C1.5 series. The machine is very similar to the older models. However, there are some differences. The important ones are mentioned in this course. Also, see Guidance for Those Familiar with Predecessor Products in the field service manual, where all the differences are described in one section.
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  • Page 6: Specifications

    PRODUCT OUTLINE The model will be introduced. The optional peripherals will be introduced. The product concept, sales points, and targets will be presented. SPECIFICATIONS The main specifications will be given. Significant items will be stressed. INSTALLATION Installation of the machine and the peripherals will be covered. Firmware update will be covered.

  • Page 7: Development And Toner Supply

    DEVELOPMENT AND TONER SUPPLY The development process will be described. Toner supply mechanisms and toner density control will also be described. Toner end detection will also be described. PAPER FEED AND CUTTING The paper feed mechanisms for the main body will be described. The cutter will also be described.

  • Page 8: Purpose Of This Section

    PURPOSE OF THIS SECTION The model will be introduced. The optional peripherals will be introduced. The product concept, sales points, and targets will be presented.
  • Page 9 No additional notes...
  • Page 10 APPEARANCE This slide shows a front view of the machine. Document feeder: One sheet at a time. Document exits at top and rear; the rear exit is not shown here Copy exits at front and rear (rear one not shown in the diagram). Bypass Tray: One sheet at a time Roll Tray 1: Contains two paper rolls (rolls 1 and 2) Roll Tray 2 (Optional): Contains two paper rolls (rolls 3 and 4).
  • Page 11 An optional paper cassette can be installed instead of an optional roll feeder. There are two trays.
  • Page 12 The table is too high for most wheelchair users.
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  • Page 14 The blue line represents the USB cable. The red dots represent the points where the cable is connected.
  • Page 15 No additional notes...
  • Page 16 This is the same option that was used with the Be-C1. Note how this option can be used to stack originals coming out of the rear exit. The diagram on the right shows how to adjust the tray to match the size of the originals.
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  • Page 20 If the folder option is installed, a stacker cannot be installed at the rear.

  • Page 21: Front View

    FRONT VIEW See Operating Instructions - About the Machine – Getting Started Copy paper sources Upper roll tray (item 8): Contains two paper rolls Lower tray (item 10): Contains two paper cassettes or paper rolls. This tray is an optional item. Bypass feed tray (item 16): Use this to make a copy on a sheet of cut paper.
  • Page 22 trailing edge of the original after scanning, to prevent it from falling and being damaged. To release the trailing edge, press the Scanner Stop key.
  • Page 23 REAR VIEW See Operating Instructions - About the Machine – Getting Started Original exit Rear exit (item 1): The original is fed out to this exit. Copy exit Rear exit (item 3): The copy is fed out to this exit.
  • Page 24 The diagram shows the upper tray. 1. Anti-humidity heater switch When humidity is high, paper in the paper tray may absorb moisture, which can affect copy quality. The anti-humidity heater prevents this. Turn this switch on when humidity is high. 2.
  • Page 25 The operation panel layout has been redesigned since the previous model.
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  • Page 31 A temperature/humidity sensor has been added below the transfer power pack to control the charge supplied by the transfer and separation power packs.
  • Page 32 No additional notes...
  • Page 33 There is no IEEE1284 option. The roll feeder and paper cassette are new options, but the only difference from the previous models is the color of the covers.
  • Page 34 There is no Ratio controller for this model.
  • Page 35 Toner The toner cartridge capacity is 800 g. The toner is the same as N-C2 and D-C2, but the toner cartridges are unique. The rear flange is different, so that you cannot install the wrong type of toner cartridge. Developer The developer bag contains 1.0 kg.

  • Page 36: Reliability Targets

    RELIABILITY TARGETS Note that the PM cycle is 10 km (length of copies made).
  • Page 37 RELIABILITY TARGETS Note that the PM cycle is 10 km (length of copies made).
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  • Page 39 In case 1, the print adds 594mm to the length counter. In case 2, the print adds 841mm to the length counter. But, in both cases the area counter stays the same. Because of this, customers who print images in the LEF orientation will get more prints from their service contracts when the machine is set on the length counter.
  • Page 40 In other machines, you cannot change the unit after you install the machine, because the machine cannot remember the history of changes for the unit. For example, we start with meters, and print 5 meters. Then we change to feet, and print 6 feet. The total is 5 + 6 feet = 11 feet, which is not correct. But with this model (same as D-C2), there is a basic counter in the software that counts in mm or mm , and converts this to the required unit.

  • Page 41: Purpose Of This Section

    PURPOSE OF THIS SECTION The most important specifications of the machine will be discussed.
  • Page 42 Originals Only one original can be fed at a time. There is no separation mechanism. Original Weight Note that the rear straight feed path can be used for heavier paper than the others. This is because there are no twists and turns in the feed path.
  • Page 43 Copy Paper Size Bypass feed: You cannot feed long sheets without some skew developing, so the maximum spec has been limited to 2 m. Maximum copy length: This is the same for all rolls. Minimum copy length: There are no rollers in the paper feed path up from roll 3 and 4 (roll tray 2), after the feed exit roller for the lower tray.
  • Page 44 Zoom Note the fine increments on the zoom. Resolution Both scanner and printer are 600 dpi. Gradation Scanning: The capability of the CIS is 256 gradations. However, the output from the IPU is two-bit (4 levels). Printing: The VDB sends the four-level data to the LED print head. However, the capability of the print head is 32 levels.
  • Page 45 Copy Number Input Note that multi-copying is only available for standard copy sizes.
  • Page 46 Copy paper capacity Don't use rolls with a larger diameter, or they will not turn in the holders. Output tray capacity ‘Application paper’ means ‘paper for special applications. It really means ‘anything except normal plain paper’. Examples would be translucent paper and film.
  • Page 47 No additional notes...
  • Page 48 PURPOSE OF THE SECTION To learn how to install the machine and the peripherals. To learn how to install the latest firmware. The slides show the important points about the installation procedure. They do not cover the complete procedure, only the important points. Go over the points on these slides before you start to install the machine.
  • Page 49 This shows the best sequence when you install the copier and all its options. If you do the steps in a different sequence, to install a component, you must remove something that you installed before.
  • Page 50 No additional notes...
  • Page 51 This is a summary of the steps of the installation procedure. Some of these will be explained in more detail. Then we will study the installation procedure. With the previous machine, it was necessary to execute SP5985-001 (NIC) and SP5985-002 (USB) to enable USB and Ethernet. This is no longer necessary.
  • Page 52 This is a summary of the steps of the installation procedure. Some of these will be explained in more detail. Then we will study the installation procedure.
  • Page 53 The machine weighs approximately 295 kg (649 lb).
  • Page 54 Adjust this panel to decrease reflections from lighting. The customer can do this adjustment.
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  • Page 57 Emphasize the note - if longer than 2 mm is left sticking above the bottom plate, you cannot pull out or slide in the optional 3 roll feeder. If the machine is not level from left to right, developer will not be distributed evenly across the development unit.
  • Page 58 If the breaker switch does not drop to the “O” position: Make sure that the power cord is securely connected to the power supply. Push the test button again. If the breaker switch does not snap down to the ‘O’ position, the breaker switch must be replaced.
  • Page 59 There are two 1-kg packs of toner provided. Do not open either pack until you are instructed to do so in the procedure Each bag contains 1 kg of developer. Earlier models had a knob which must be turned to distribute developer. In this machine there is no knob.
  • Page 60 Install the toner cartridge before you input lot numbers and initialize developer. You must shake the toner cartridge to make the toner loose inside the cartridge. If not, torque in the mechanism is too high and the development unit is damaged. In case you forget, a slip clutch was added to the mechanism between the toner hopper and the toner supply clutch to prevent this damage.
  • Page 61 This is a temporary installation. It is needed to continue with the developer installation procedure. The cartridge must be physically in the machine, but toner must not be added. So don’t remove the tape.
  • Page 62 The drum motor should switch on as soon as the machine warms up. However, the motor may not switch on immediately if the temperature of fusing unit is below 50°C (122°F). After installing the first bag, you must turn on the machine to distribute the developer evenly inside the development unit.
  • Page 63 No additional notes...
  • Page 64 A decal on the left side of the machine explains how to install the toner cartridge.
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  • Page 68 Then do the two SP modes listed on the slide. Do not attempt to make copies yet. SP2801 (Developer Initial Setting) This prepares the developer for copying by agitating it for about two minutes, which brings the electrostatic charge on the developer to the correct level.
  • Page 69 To send the machine from the factory, the blade is away from the drum. After Drum Set Mode, move the blade until it touches the drum (move the lever right), where it will stay during standard operation. The first time that the drum turns, the layer applied during Drum Set Mode will be cleaned off.
  • Page 70 SP 3001 002 Initializing the ID sensor takes about 6 seconds. After it is finished, two numbers are displayed. PWM is the power applied to the ID sensor, and Vsg is the output when measuring the light reflected from the bare drum.
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  • Page 73 This is not important for the rear original exit.
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  • Page 78 The lever is shown on a previous slide. The shipping position is the left. We move it to the right after installation, but we must move it to the left again before we move the machine.
  • Page 79 If you move the machine a short distance within the same room, it is not necessary to do these things. But, after installation, if you move it a long distance (for example, between a warehouse and the customer location), you must do the two steps on the slide.
  • Page 80 This unit allows the user to install another two rolls of paper. Take care when lifting the unit. It is quite heavy and will need up to four people to install. Go over the next few slides before starting to install the machines.
  • Page 81 Study the diagrams and follow the notes in the manual. This will help you to figure out which rail should go on the left and which on the right, and which way up they should be. Which way round to install the guide? See the diagram on the slide.
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  • Page 85 In particular, take care when lifting the unit. It is quite heavy and will need up to four people to install.
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  • Page 87 This procedure requires at least two technicians. The previous model required a scanner relay board and a printer relay board, but these are not needed with this new model.
  • Page 88 This is an overview of the procedure. See the service manual for the complete procedure. The procedure is changed a lot from the previous machine.
  • Page 89 There is no Ratio controller for this model.
  • Page 90 No additional notes...
  • Page 91 Applications can be moved to the card in slot 1. Service Manual, Installation, MFP Options, Before You Begin, Moving Applications onto one SD Card There is no special location inside the machine to keep SD cards that have been copied.
  • Page 92 When you use the ‘Undo Exec’ procedure, the SD card in Slot 1 must be the original SD card of the application you want to move from Slot 2 to Slot 1. You cannot use any blank SD card in Slot 1. The application can be moved only to the original SD card.
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  • Page 98 Service manual, System Maintenance Reference, Firmware Update SP 7801: This shows the firmware versions. If the update procedure fails, you must replace the controller board.
  • Page 99 If you move the machine a short distance within the same room, it is not necessary to do these things. But, after installation, if you move it a long distance (for example, between a warehouse and the customer location), you must do the two steps on the slide.
  • Page 100 PURPOSE OF THE SECTION The components will be discussed briefly. The machine’s organization and overall PCB structure will also be covered.
  • Page 101 Important points about the major units are as follows: 1. Image Writing Unit: Uses an LPH (LED Print Head) capable of 32-level gradation to write 2-bit image data. 2. Scanner Unit: Uses a CIS for 256-level scanning. 3. Cleaning Unit: The drum is cleaned with a counter blade. 4.
  • Page 102 Front Copy Tray OPC Drum Original Table Charge Corona Unit Cleaning Unit Original Feed Rollers Original Exit Rollers Upper Original Exit Rollers Upper Original Exit Guides 10. Original Exit Junction Gate 11. Upper Exit Rollers 12. Fusing Cleaning Roller 13. Paper Exit Junction Gate 14.
  • Page 103 32. Registration Rollers 33. Development Unit 34. Toner Cartridge...
  • Page 104 A) Paper path from the by-pass feed table B) Paper path from the 1st/2nd roll tray C) Paper path from the 3rd/4th paper tray (option) D) Original paths Original Feed Paths There are two exits: upper, and rear. An optional original exit table can be installed behind the machine to catch originals coming out of the machine.
  • Page 105 This shows the paper path when the optional cassette unit is installed instead of the optional roll feeder. The diagram shows the Be-C1, which is very similar.
  • Page 106 No additional notes...
  • Page 107 1. Original Feed Motor 2. Drum Motor (in this new model, this motor drives the transfer roller as well as the drum) 3. Registration Motor 4. Roll Feed Motor 2 5. Roll Feed Motor 1 6. Development Motor 7. Fusing/Exit Motor Original feed motor - original feed mechanism Drum drive motor –...
  • Page 108 This slide shows the optional paper cassette unit installed instead of the optional roll feeder. The diagram shows the Be-C1, which is very similar.
  • Page 109 Boards The BCU controls the machine. The IPU controls the image processing. The IOB controls the mechanical components. It also performs process control, transfers serial data between the machine and peripherals, and controls the fusing unit. Do not adjust the dip switches in the field.
  • Page 110 Boards (continued) AC CTL Board: This is the connection point for the main power supply. It controls the power supply to the PSU, fusing lamps, and all heaters. HVPS: Two power packs (High Voltage Power Supply). The CGB power pack provides is the power supply for the charge, grid, bias applied to the drum.
  • Page 111 SIB.
  • Page 112 PURPOSE OF THE SECTION Common procedures will be discussed. Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings. Covers This new machine has the same number of covers as the previous machines.
  • Page 113 How to start from shutdown To start the machine, press the main power switch. However, if you press the main power switch between the beginning and the end of a shutdown, the machine will not start.
  • Page 114 No additional notes...
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  • Page 119 This is a view with the controller box cover removed.
  • Page 120 The replacement procedure in the service manual contains a table of switch settings for each area.
  • Page 121 No additional notes...
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  • Page 124 The browser unit SD card is linked to its machine (the machine serial number is registered on the SD card). So a card that has already been installed on one machine cannot be used on another.
  • Page 125 No additional notes...
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  • Page 128 PURPOSE OF THIS SECTION This section describes the original feed and scanner mechanisms.

  • Page 129: Scanner Layout

    SCANNER LAYOUT The diagram shows the dimensions of the scanner. A 600 dpi CIS (contact image sensor) is used in this machine. There are ten original size sensors. The original set sensor also takes part in original size detection. The white platen plate is used for auto shading (to get the standard white level for image processing).
  • Page 130 Only one sheet can be placed in the feeder at a time. There is no separation mechanism. There are two original exits.
  • Page 131 For recommendations on which exit to use, see the Operating Instructions. Copy/Document Server Reference > Basic Copying > Original and Copy Output Locations...
  • Page 132 The original set sensor detects A4 or B4 SEF and North American A size originals. The original size sensors detect larger sizes. The original set sensor is in the centre of the main scan, so it detects any paper that is put in the feeder.
  • Page 133 No additional notes...
  • Page 134 There are two delays to allow the user to correct for skew and other feeding problems before the scan begins. They are controlled with user tools as shown on the slide. The machine feeds at 105 mm/s as far as the registration roller. From that point, the feed speed depends on the reproduction ratio.
  • Page 135 No additional notes...
  • Page 136 SP 4962 can be used to check if the sensor is working. See the SP table for details.
  • Page 137 This feature can be switched off and on with SP4975. The default setting is on (the rollers do not release the trailing edges of originals longer than 450 mm). This SP must be turned off if a rear original stacker is used. Otherwise, only one original can be fed at a time.
  • Page 138 The CIS can only be replaced in the field as a unit. The scanner is controlled by two boards, the CIS IF board and the SIB. The CIS IF provides the interface for the LED arrays with the SIB. The SIB controls the LEDs and the scanning unit sensors.
  • Page 139 Each block contains a latch and shift register, so assembling the video signal is 8 times faster than with all the elements in one big block.
  • Page 140 No additional notes...
  • Page 141 The base white level (absolute white) is taken from the white platen plate - auto shading. Then, every line, the machine checks the background and removes that from the image. The background is checked from a 140 mm wide strip in the middle of the original.
  • Page 142 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
  • Page 143 No additional notes...
  • Page 144 PURPOSE OF THE SECTION This section will describe drum drive, the charge corona unit, drum cleaning, and quenching.
  • Page 145 These are the most important components around the drum. The paper passes the drum at 120 mm/s (D208) or 170 mm/s (D211); this is the same speed as the previous models in this series. However, the fusing motor pulls a little faster. This will be discussed in the Fusing section of the course.
  • Page 146 In the previous models of this series, the drum motor controlled the drum only.
  • Page 147 No additional notes...
  • Page 148 It’s a single wire, but it’s looped so there are actually two wires crossing the drum. The main point to note about this unit is that the grid consists of a number of parallel wires strung along the length of the charge corona unit. The mesh-type grid system is a better method.
  • Page 149 The motor turns a worm gear. This gear pulls the wire that is attached to the cleaner. The wire cleaner first goes to home position (at the front, by the motor). Then it moves to the rear (by the sensor), then to the home position again. The corona wire is cleaned immediately after the main power switch or operation power switch is switched on, if these two conditions occur: The temperature of the hot roller is less than 50˚C (122˚F).
  • Page 150 A counter blade cleans more effectively. The drum turns anti-clockwise as seen in this diagram. Also, remember the Drum Set Mode procedure (SP 2923) during installation, in which the cleaning blade is kept away from the drum while the drum is coated with toner.
  • Page 151 Before doing the Drum Set Mode procedure, move the cleaning blade lever to the left (as seen from the front of the machine) to make sure that the blade is away from the drum. The diagram on this page is a side view. The three-dimensional view at the top right is a rear view, so the handle moves in the opposite direction from the one in the Installation section.
  • Page 152 The capacity of the used toner bottle is 4600 cc (about 25.3 k copies/A1 sideways [LEF] or 15 km at 6% coverage). The sensor is half way between the spout and the side of the machine, so there should not be many premature alarms caused by piles of toner building up in front of the sensor.
  • Page 153 No additional notes...
  • Page 154 The lamp contains red LEDs to prevent drum fatigue. The quenching lamp used in this new machine has 3 elements. The lamp in the previous model has 2 elements. The angle of the quenching lamp was changed to achieve maximum coverage on the drum.
  • Page 155 The heaters are off when the main power is on, and on when the main power switch is off. These are standard components of the machine, not optional items.
  • Page 156 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
  • Page 157 No additional notes...
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  • Page 159 Follow the cautions in the manual. Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual).
  • Page 160 Follow the cautions in the manual. Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual).
  • Page 161 No additional notes...
  • Page 162 Follow the instructions in the ‘Drum, Drum Cleaning Blade Removal’ procedure for how to disassemble the drum unit.
  • Page 163 No additional notes...
  • Page 164 PURPOSE OF THE SECTION The latent image writing mechanism will be described. This machine uses LED arrays, and not lasers, so there are no safety switch circuits to describe.
  • Page 165 Illuminated areas of the drum drop to - 50 V (with a tolerance of +20V and - 30V). Un-illuminated areas are at -900 V ±40V.
  • Page 166 There is a small problem with copy quality at the joints between the heads, as will be seen later in this section.
  • Page 167 SP 2940 0: On when motors on (default) 1: Always off 2: On at same time as fusing lamps...
  • Page 168 The LEDs in the print head light at 10% of their full power. To make the 32 grades, the power is divided into 32 equal intervals. For example, if the gradation for a certain pixel is 17, the LED for that pixel will be on at 17/32 of the power.
  • Page 169 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
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  • Page 172 SP settings on the decals This decal is only on the spare parts, not on the original part installed at the factory. See the factory setting sheet for the original factory settings. Before re-installing the right copy tray, read the LPH settings from the labels attached to the LPH.
  • Page 173 LPH REPLACEMENT AND ADJUSTMENT What are these settings?, continued The diagram shows the LPH unit, above the drum. There are three heads, LPH 1, LPH 2, and LPH 3. LPH 2 is in the centre. Clearly, they are not in the same position above the drum in the sub scan direction.
  • Page 174 Details are in the following section of the service manual: Replacement and Adjustment, Important Adjustments, LPH Adjustment with SP Codes Printing the Test Pattern The pattern appears something like shown on the slide. Note the faint lines one third and two thirds of the way across. These are the joints.
  • Page 175 Adjusting the SP Settings If the SP settings are as little as one pixel out, you will see a clear white or black line, like in the above example. On the left, too many LEDs are switched off and the result is a white line.
  • Page 176 Adjusting the SP Settings The top diagram shows how the LEDs should light. The bottom diagram shows not enough LEDs lit at the left joint and too many at the right joint. On the test pattern, this will cause a white line one-third of the way across, and a black line two-thirds of the way across.
  • Page 177 LED HEAD MISALIGNMENT In the example on the slide, the LEDs in head 2 are not directly in line with those in head 1. A similar situation will occur between heads 2 and 3. If there is an overlap at the joint, a black line will occur on the printout if both overlapping LEDs are lit.
  • Page 178 Adjusting the SP Settings, continued The three LED heads are not in a straight line across the page. See the top diagram - the difference between the two at left and right is exaggerated, but we need to point out that the heads at left and right are also not exactly lined up.
  • Page 179 Adjusting the SP Settings, continued If the test print out is disjointed, adjust SPs 2952 011 and 012 by trial and error until the main scan lines are printed correctly. Adjust SP 2952 011 first. This takes LPH 1 as the base for the adjustment, and corrects the timing for LPH 2 relative to that.
  • Page 180 No additional notes...
  • Page 181 PURPOSE OF THE SECTION The development process will be described. Toner supply mechanisms and toner density control will also be described. Toner near-end and end detection will also be described.
  • Page 182 The toner cartridge is installed in the development unit (at the top left in the drawing).
  • Page 183 1. Auger 2. Doctor Blade 3. Development Entrance Seal 4. OPC Drum 5. Development Roller 6. Paddle Roller 7. Toner Agitator 8. Toner Cartridge 9. Separator 10. Development Filter The paddle roller picks up developer and transports it to the development roller.
  • Page 184 The development units of these machines and the previous machines are not interchangeable.
  • Page 185 This slide shows how toner and developer are mixed in the development unit to make the toner density equal in all parts of the development unit. The quantity of developer moved right by the backspill plate is the same as the quantity moved left by the mixing auger.
  • Page 186 Copying The development bias is -600 V. ID Sensor Patterns The main point to note here is that the machine has two ways of making the ID sensor patterns. These are Low Duty Mode and High Duty Mode. The mode used depends on SP 2201 004. In this machine, there should be no need to change the low/high duty mode setting (see the next slide).
  • Page 187 This machine has a higher estimated ACV than the D, so the default setting was changed from low duty mode to high duty mode. It is thought that it will not be necessary to change this setting in the field for this machine.
  • Page 188 No additional notes...
  • Page 189 This slide shows how toner gets to the development unit from the toner cartridge, and how it mixes with the developer in the development unit. The toner goes directly to the development unit from the cartridge. There is no hopper between the cartridge and the development unit. But the cover where the cartridge is installed is known as the ‘hopper cover’, and the area where the cartridge stays is known as the ‘hopper’.
  • Page 190 For example, if the first copy after an ID sensor pattern check is 90 cm long, there will be no ID sensor pattern check after the copy (less than 100 cm made). Then, if the next one is 50 cm long, 140 cm will have been copied since the last check, so the ID sensor pattern is checked after printing the 50 cm copy.
  • Page 191 No additional notes...
  • Page 192 The most important point to note is that the machine cannot automatically switch modes when the sensor breaks, or when a new one is installed. SC400 to 406 will occur if the ID sensor fails. This is a D type code, so copying will still be possible after the machine is switched off/on.
  • Page 193 Vsp: ID sensor reading from the bare drum Recovery from Near-end If Vsp/Vsg drops below SP 2927 001, the machine is released from the near-end condition.
  • Page 194 No additional notes...
  • Page 195 There are no field service adjustments, so there is no need to go over the process in in detail. Changing related SPs could cause developer to get on the drum (which would damage the drum) or on the copies (which would damage the hot roller).
  • Page 196 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
  • Page 197 Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual).
  • Page 198 No additional notes...
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  • Page 202 Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual).
  • Page 203 PURPOSE OF THE SECTION The paper feed mechanisms for the main body will be described. The cutter will also be described. The optional cassette feed unit will be dealt with in a later section. The mechanisms for the optional roll feeder are the same as for the main body.
  • Page 204 Each roll tray unit contains a cutter. The cutter cuts the paper after the specified paper length has been fed. The amount of paper fed is monitored by the cutting sensor. The starting time of the cutter depends on the cutting mode selected at the operation panel (preset cut, synchro cut, or variable cut) After paper has been cut, the roll must be reversed to a standby position away from the cutter.
  • Page 205 1. Registration Roller 2. By-pass Feed table 3. Cutting Sensor 1 4. Feed Exit Roller 1 5. Cutter 1 (Upper Tray) 6. 1st Roll Lead Edge Sensor 7. 2nd Roll Lead Edge Sensor 8. 1st Feed Roller 9. 1st Roll Paper End Sensor 10.
  • Page 206 24. Roll End Sensor 2 25. Roll End Sensor 1...
  • Page 207 No additional notes...
  • Page 208 A roll holder fits into the end of each roll. The roll holders can be easily moved to a different place to change the paper size. There are no paper size sensors attached to this mechanism.
  • Page 209 Note the user tools that must be used for paper type and other roll-related displays on the operation panel. Note how the settings affect the display panel. Paper type and width affect toner supply and fusing temperature/pressure, so the correct settings should be made. Paper type Rolls 1 to 3: Plain, Translucent (tracing paper), Film, Recycled Bypass: Plain, Translucent (tracing paper), Film...
  • Page 210 No additional notes...
  • Page 211 Roll 1 is driven by roll feed motor 1 and roll feed clutch 1. Roll 2 is driven by roll feed motor 1 and roll feed clutch 2. Roll 3 is driven by roll feed motor 2 and roll feed clutch 3. Roll 4 is driven by roll feed motor 2 and roll feed clutch 4.
  • Page 212 There is no by-pass roller mechanism. The bypass feed sensor is just before the registration roller. When the bypass feed sensor detects the paper, the registration motor and clutch feed the paper to the registration sensor. When the paper reaches the registration sensor, the machine makes a beep. If there is no beep, the paper didn’t reach the sensor.
  • Page 213 The registration motor also drives the toner collection coil, so both a motor and clutch are needed for the registration roller.
  • Page 214 When the trailing edge of the paper is 50 mm before the registration sensor, the speed of the registration roller is increased 2%. The speed does not reach the speed of the fusing rollers. Jitter: A type of image distortion caused by toner particles being shaken from their original position on the paper.
  • Page 215 There is a cutter for each tray (two cutters in total). The cutter is a rotary disk that cuts the paper by pressing it against a metal plate and moving across the paper. The cutter motor moves the cutter across the paper. The cutter can move in either direction.
  • Page 216 The cutter cuts the paper after the specified paper length has been fed. The amount of paper fed is monitored by the cutting sensor. The starting time of the cutter depends on the cutting mode selected at the operation panel (preset cut, synchro cut, or variable cut) After paper has been cut, the roll must be reversed to a standby position away from the cutter.
  • Page 217 Roll end sensors (circled in red) These are reflective photosensors. The paper rolls for this machine have a black core. So, when paper runs out, light is not reflected from the core back to the photosensors. Paper end sensors (circled in blue) Normally, there is always paper at these sensors, unless the roll runs out.
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  • Page 221 There are four heaters for each tray (total 8). The heaters are standard components, not options. The switches (circled in red) determine what happens when the main power is off. These switches are set to OFF before the machine leaves the factory. Each switch is at the rear left corner of the tray.
  • Page 222 Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual). Adjust the cut length with SP 1920 after changing the feed rollers. There are SPs for rolls 1 to 4. Use the adjustments for the roller that was replaced.
  • Page 223 PURPOSE OF THE SECTION Image transfer and paper separation mechanisms will be described. Transport from the drum to the fusing unit will be explained.
  • Page 224 The strength of the charge on the transfer roller can be adjusted for the type and thickness of the paper in use.
  • Page 225 In the previous machine, the transfer voltage and the separation voltage were supplied by a single board, the T&S power pack. However, in this machine there are two boards. A Transfer Power Pack supplies the transfer voltage and a Separation Power Pack supplies the separation voltage.
  • Page 226 No additional notes...
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  • Page 228 This sensor is new for this series.
  • Page 229 No additional notes...
  • Page 230 This is a back-up mechanism, in case the separation mechanism fails to separate the paper from the drum. When the leading edge of the paper on the drum enters the separation corona unit with about 198 mm (7.8") of the paper in contact with the drum, the solenoid switches on.
  • Page 231 The left-hand drawing shows the location of the transport belt and the fans. There are two fans. The right-hand drawing shows the flow of air out through the ozone filter. The fans also cool the fusing unit. The fans stay on during standby mode to keep the machine cool. The speed of the separation/transport fan accelerates slightly as soon as a job starts with Film Mode 4 selected.
  • Page 232 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
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  • Page 236 PURPOSE OF THE SECTION The fusing unit and fusing temperature control will be described.
  • Page 237 The arrangement of fusing lamps and thermistors is the same as for the previous model.
  • Page 238 No additional notes...
  • Page 239 No additional units...
  • Page 240 The wattages of the lamps are different for each model also. The connectors for the lamps are different, so it is not possible to install the lamp for the wrong machine. D211 hot roller The roller contains three pipes with liquid in them. The liquid circulates when the fusing lamps turn on.
  • Page 241 Other differences between the two machines Hot Roller D208: Diameter: 60 mm, thickness: 1.6 mm D211: Diameter: 60 mm, thickness: 2.1 mm; contains a heat pipe roller Pressure Roller Diameter: 65 mm, thickness: 85 mm (same for both models) Pressure Motors Automatic pressure adjustment for both.
  • Page 242 This is for plain paper mode 3, which is the default condition. For other paper type settings, the copy ready temperature is the same as the target temperature.
  • Page 243 This is also for plain paper mode 3.
  • Page 244 No additional notes...
  • Page 245 Each motor pulls a spring, which moves a lever that applies upward pressure on the end of the pressure roller shaft. The pressure roller is hollow, so the shaft does not affect the pressure at the ends of the pressure roller. Bushings at the centre of the shaft push upwards, and this applies the upward pressure between the hot roller and pressure roller.
  • Page 246 This slide and the next one show the mechanism in more detail.
  • Page 247 This slide shows the shaft running through the centre of the pressure roller. The bearings apply upward pressure near the centre of the pressure roller. This is different from most copiers. Pressure is normally applied between the ends of the shaft. The bearings are fixed in position with e-rings.
  • Page 248 The graph shows how the nip width changes across the width of the fusing unit. The dotted line going across the centre shows the ideal nip width. The vertical dotted line marks the mid-point of the fusing unit, across the paper path.
  • Page 249 There is no oil supply unit. The cleaning roller’s coating is saturated in silicone oil, which cleans the hot roller. Helps prevent problems caused by paper that is coated with calcium carbonate.
  • Page 250 No additional notes...
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  • Page 252 Also, at about the same time, the registration motor speeds up slightly, as described in the Paper Feed section. The speed control adjustment is not done for paper shorter than 250 mm (9.8 in.) Fusing starts after the line speed has been slowed and the trailing edge has left the registration roller.
  • Page 253 When the paper reaches the fusing unit, the fusing motor starts to pull the paper through the machine and out of the exit. However, when the paper reaches the fusing unit, if it starts to move past the drum faster, the image will be enlarged in the sub scan direction. To counter this, the registration motor and fusing motor both slow down by the same amount, to maintain constant magnification.
  • Page 254 There are three adjustment levers at the center of the fusing unit entrance. The levers can be moved left and right to adjust the height of the entrance guide plate. Adjust only when the paper thickness is causing a severe problem at the fusing entrance.
  • Page 255 PURPOSE OF THE SECTION Only the main points will be mentioned here. For full details of all procedures, see the service manual. Follow all the steps carefully, and take note of all notes, cautions, and warnings.
  • Page 256 Make sure that you are aware of the SP modes that must be done after each procedure (they are in the procedures in the manual). FPDB The diagram is a rear view. So, the right FPDB is on the left side of the drawing and vice versa.
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  • Page 260 PURPOSE OF THE SECTION The paper exit mechanisms will be described.
  • Page 261 When using the front exit, the trailing edge of the paper is grabbed, so that the output does not fall on the floor.
  • Page 262 No additional notes...
  • Page 263 The solenoid directs the paper to either the front or rear copy exit. The user selects the required exit for the job at the operation panel. The procedure for the user to switch between the exits was shown in the Machine Overview section of the course. For recommendations on which exit to use, see the Operating Instructions.
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  • Page 266 PURPOSE OF THE SECTION This is a quick overview of PM for this machine.
  • Page 267 The PM cycle is 10 km of printouts. Not all items need PM at 10 km. Some only need PM at 20, 30, 40 km, and so on. See the PM table for details. Development filter: If this is blocked, air pressure may increase inside the development unit, and this may lead to toner scattering.
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  • Page 269 See ‘Replacing PM Parts’ in the maintenance section of the service manual for the correct way to reset a PM counter.
  • Page 270 No additional notes...
  • Page 271 PURPOSE OF THE SECTION This describes the mechanisms in the optional paper cassette.
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  • Page 273 This slide shows the optional paper cassette unit installed instead of the optional roll feeder. The cassette feed motor drives both trays. Each tray has a clutch.
  • Page 274 The relay roller in the main body (in the blue circle in the diagram) lets the cassette unit feed short paper (A4 LEF is the minimum)
  • Page 275 The tray lift sensor detects the top of the stack and tells the lift motor to stop. This sensor is not shown in the diagram. The paper near-end sensor detects when the bottom plate is getting high. This means that paper is almost finished. This sensor is shown on the diagram.
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  • Page 277 The manual shows which sizes are detected automatically. Other sizes must be specified with the user tool.
  • Page 278 For example, after the wheel turns 40.5 degrees, the state of CN2 changes to HIGH.
  • Page 279 This example shows how the sensor operates for international paper sizes. For some sizes, the length sensors must be used to detect the correct size, because the rotary switch output is the same. For A4 LEF and A3 SEF, these widths are the same, so the width sensor cannot distinguish them.
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  • Page 282 The End...