Page 1 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE COURSE OVERVIEW The course is broken up into several modules. This section outlines these modules. The course covers the HP4-V2 and the optional peripherals. Software is covered in separate courses. The mechanisms are very similar to the Pink Gold/HP4 and Silver duplicator series.
Page 2: Course Overview
21/12/2009 Course Overview Product Outline Specifications Installation Operation Machine Overview Scanning Image Processing PRODUCT OUTLINE The model will be introduced to the class. The optional peripherals will be introduced to the class. The product concept, sales points, and targets will be presented. SPECIFICATIONS Significant items will be discussed.
Page 3 21/12/2009 Course Overview Master Ejection Master Feed Drum Paper Feed Paper Delivery Maintenance Troubleshooting Optional ADF MASTER EJECT This section explains how the used master is removed from the drum before the new master is wrapped around the drum. MASTER FEED This section explains how the new master is wrapped around the drum.
Page 4 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE PRODUCT OUTLINE Page 4...
Page 5 21/12/2009 PRODUCT CONCEPTS AND MAIN SALES POINTS Page 5...
Page 6 21/12/2009 Appearance Operation Panel with Large LCD Screen Paper delivery table (capacity 1,000) Paper feed table (capacity 1,000) The LCD is not a touch-panel. Page 6...
Page 7: Product Concept
21/12/2009 Product Concept Mid-range model with more capabilities than current models in this range Replacement for the HP4 and Pink Gold models The engine is based on the Pink Gold series. Page 7...
Page 8 21/12/2009 Options 50-sheet Document Feeder Colour Drum A4 Drum (black only) Tape Dispenser Platen Cover There is no sorter, Opal, or LCS. The drums cannot be used with the Opal or HQ-Opal. Introduce the range of available options. The document feeder is the same as used with the Sapphire 2 and HP4. The tape dispenser is almost the same as used with previous models.
Page 9 21/12/2009 Platen Cover/ADF The customer needs one of the above options. This is because a platen cover is not installed at the factory. Page 9...
Page 10: Sales Points
21/12/2009 Sales Points Good image quality High-quality ink and masters Quiet Sound-proofing materials are added to areas where noise occurs Noise-generating mechanisms are modified Reliable Improved paper delivery table Paper feed retry Ink and masters: Same as the HP4 Slightly quieter than HP4, because of these modifications Paper delivery table: The new mechanisms from the Emerald are used.
Page 11 21/12/2009 Sales Points Energy saving User-friendly Four-line LCD screen Exchangeable ‘Master Making’ and ‘Print’ keys The controller is a new model. Page 11...
Page 12 21/12/2009 Good Image Quality Old Type High-quality Ink and Masters New Type Same as the HP4. In older models, fibres in the master were sometimes tangled. This blocked the flow of ink through the master to the paper. The new master is improved. Also there is an additional porous layer, the film is thicker, and the holes in the master are sharper.
Page 13 21/12/2009 Good Image Quality High-quality Ink and Masters As a result Better solid fill-in Smoother halftone and photo images • In addition to the improved master and ink, image processing is similar to that used in black-and-white copiers. This means that all types of originals (text, photo, text/photo) can be reproduced accurately.
Page 14 21/12/2009 Good Image Quality Auto Print Pressure Control Without auto print pressure control: The print is paler if the print speed is faster The print is darker if the temperature is higher There is a thermistor near the drum to detect temperature.
Page 15 21/12/2009 Reliability Paper Delivery Table Improved paper delivery table: Plates are attached on each side The tabs on the inner sides of the plates catch the edges of the paper. Because of this, the paper falls more slowly onto the delivery table. This reduces ink stains on the rear sides and stacks the pages more...
Page 16 21/12/2009 Reliability Paper Feed Retry Paper feed retry If the registration sensor does not detect the paper feeding into the machine, the feed mechanism tries again. Same as the HP4. Page 16...
Page 17: Energy Saving
21/12/2009 Energy-saving This model has energy saver and auto-shut off modes, like photocopiers. Compliance with directives on hazardous materials (RoHS) and waste (WEEE). Auto off mode is new for this series. Page 17...
Page 18 21/12/2009 User-friendly Operation Panel Four-line LCD (not a touch-screen) Improved operation panel design Important buttons near the screen Not often used buttons under a cover at the left side of the operation panel Page 18...
Page 19 21/12/2009 User-friendly Exchangeable Keys A technician can exchange the ‘Master Making’ and ‘Print’ keys. Some customers may prefer the keys to be exchanged. The functions of the two keys automatically change when you do this. The procedure is in section 3.2.3 of the service manual. Page 19...
Page 20 21/12/2009 YIELD AND RELIABILITY TARGETS Page 20...
Page 21 21/12/2009 Supply Yield Targets Masters The master rolls are compatible with the HP4. • A3 drum: 200 masters/roll • Optional A4 drum: 315 masters/roll • 4,000 prints/master Ink (black, coloured) The ink cartridge is compatible with the HP4. • 600 ml/cartridge Ink Type For more details on ink consumption, see ‘Handout 1 –...
Page 22 21/12/2009 Reliability Targets Maximum copies per master 4,000 Monthly Print Volume Average: 50k Maximum: 170k Estimated Unit Life 10,000k prints, 30k masters, or 5 years PM Cycle 1200k or 6 months MCBC 240k Page 22...
Page 23 21/12/2009 Serviceability Targets Maintenance Time 6-months PM: 20 minutes 12-months PM: 50 minutes EM: 40 minutes Installation Time Mainframe: 20 to 30 minutes ADF: 10 minutes Page 23...
Page 24: Specifications
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE SPECIFICATIONS Go through the machine’s specifications. Emphasize the points listed on the slides. Page 24...
Page 25 21/12/2009 Specifications 1 Resolution Thermal head: 400 dpi Scanning: 400 x 400 dpi • CCD resolution (main-scan) is 600 dpi, but the circuits change this to 400 dpi Original Size Maximum 300.8 x 432 mm / 11.8" x 17.0“ • With ADF –...
Page 26 21/12/2009 Specifications 2 Printing Area A3 drum: 290 x 410 mm / 11.4" x 16.1" A4 drum: 290 x 200 mm / 11.4" x 7.8" Acceptable Paper Sizes Maximum: 297 x 432 mm / 11.6" x 17.0" Minimum: 70 x 148 mm / 2.8" x 5.9“ Copy Paper Weight 47.1 ~ 209.3 g/m , 12.5 ~ 55.6 lb...
Page 27 21/12/2009 Specifications 3 Printing Speeds: 60, 75, 90, 105, 120 sheets/minute Master Processing Time (at 100% size, platen mode) Less than 24 seconds (A4) Less than 29 seconds (A3) Master Eject Box Capacity: 65 masters Paper Feed Table Capacity: 1000 sheets Paper Delivery Table Capacity: 1000 sheets Page 27...
Page 28 21/12/2009 Specifications 4 Master roll specifications Thermal master roll type: • 320 mm width, 110 m/roll (A3 master roll) Yield: • 200 masters/roll (A3 Drum) • 315 masters/roll (A4 Drum) Maximum run length per master: • 4,000 prints Page 28...
Page 29: Installation
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE INSTALLATION Install at least one machine with all options as a complete system. Service Manual, section 1.1 Go over the environment, machine level, minimum space, and power requirements of the machine before proceeding with installation.
Page 30 21/12/2009 Main Body Install the machine. When you lift the machine, always use the carrying handles, as explained in the manual. If you install the optional table, make sure to attach the machine to the table with the screws (see the note in the service manual).
Page 31 21/12/2009 Options Platen cover ADF, and ADF stabilizers You must install the stabilizers, or the machine could fall over if the ADF is open Tape dispenser If you install the tape dispenser, turn on the power switch of the dupicator first, then the power switch for the tape dispenser. Optional drum For A4 drums, only black ink is supported.
Page 32: Updating The Firmware
21/12/2009 Updating the Firmware SP 8-1: Copies firmware from a flash memory card to the machine. SP 8-2: Copies firmware from the machine to a flash memory card. SP 1-70: Displays the part number and suffix of the current firmware SP 1-73: Displays the main firmware version.
Page 33 21/12/2009 Other SP Modes SP3-1: Input the present time SP3-2: Input the telephone number for service SP3-4: Input the installation date Input the data for these SPs at installation, depending on your service policy. Page 33...
Page 34: Operation
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE OPERATION This part of the course will deal with general operation and copying. Teach and demonstrate procedures from the operation manuals. Select the items to be taught in the class in accordance with the experience level of the trainees.
Page 35 21/12/2009 COMPONENTS This section explains the machine’s components from the user’s point of view. Page 35...
Page 36 21/12/2009 Machine Exterior Operation Manual, Machine Exterior Go over the major components of the machine from the user’s point of view. Be sure that the class understand the following components 4. Master tray: Open here to replace the master roll 5.
Page 37: Machine Interior
21/12/2009 Machine Interior Operation Manual, Machine Interior Go over this briefly. The document feeder is an option. Be sure that the class understand the following components 3. Paper alignment wings: Lift or lower the wings according to the type of paper used, to stack the paper neatly.
Page 38: Operation Panel
21/12/2009 Operation Panel Operation Manual, Control Panel Keys Make sure that the class are familiar with the operation panel keys. There may be some keys that are not be familiar to photocopier technicians. These keys are used to access the various features of this machine. The features will be mentioned later in this section.
Page 39 21/12/2009 Indicators Operation Manual, Control Panel Indicators Make sure that the class are familiar with the operation panel indicators. Be sure that the class understand the following items. 1. Special feature indicator: Lets you know when one or more of the keys under the cover at the left of the operation panel (item 12) has been selected.
Page 40 21/12/2009 PREPARING TO PRINT This section explains some basic points about originals and copy paper, and how to set up the machine. Page 40...
Page 41 21/12/2009 Originals Note that some types of originals may not be detected properly. Originals should not have dark areas or bold characters right at the leading edge, or the prints may have dirty edges. Note that there is a 5 mm margin at the leading edge of the original and a 2 mm margin at the trailing edge which will not be copied, even if the original is positioned correctly.
Page 42 21/12/2009 Notes Concerning A3 If you use an A3 original, use a reproduction ratio to reduce the image size, to make sure that you get all of the image on the copy paper. When you use A3, 11" × 17" and 209.3 g/m2 , 55.6 lb paper, slow the printing speed down to Setting 1, 2 or 3.
Page 43 21/12/2009 Dealing with Paper Curl Operation Manual, Operation, Print Paper Printing Paper Note the recommended sizes and types of paper. Page 43...
Page 44: Paper Feed Table
21/12/2009 Paper Feed Table Lock Lever Side Fences Operation Manual, Operation, Printing Preparations Note the correct way to set up the feed table. Raise the lock lever before you move the side fences. Then lock the side fences after you add paper. Page 44...
Page 45 21/12/2009 Paper Delivery Table Overview These items can be adjusted. Side and end plates: Move these to the correct paper size Paper alignment wings Chocks (buffer fins) These items must be adjusted manually. Page 45...
Page 46 21/12/2009 Paper Delivery Table Adjustments Chocks Buffer Fins Paper Alignment Wings Three settings: Up, Down, 45 degrees Operation Manual, Operation, Printing Preparations Note the correct way to set up the delivery table. In this machine, the side and end fences are not the only items to adjust. The paper alignment wings and chocks must be adjusted to match the paper size and thickness.
Page 47 21/12/2009 Paper Delivery Table Recommended Settings This table, from the operation manual, shows the recommended settings for each paper type. Page 47...
Page 48 21/12/2009 Folding up the Paper Feed and Paper Delivery Tables Study the correct procedures in the operation manual, to prevent damage to the machine. Operation Manual, Operation, After Printing Page 48...
Page 49 21/12/2009 BASIC PRINTING PROCEDURE This explains the basic procedure for how to make copies. Page 49...
Page 50 21/12/2009 Auto Cycle On or Off The basic printing procedure depends on whether Auto Cycle is on or off. Go on to the next slide. Page 50...
Page 51: Auto Cycle
21/12/2009 Auto Cycle Auto Cycle Faster copying of a series of originals No pause between originals, so no proof copies can be made Default: On (User Tools – System Settings – Mode Setting – Auto Cycle) Auto Cycle allows faster copying of a series of originals. Auto Cycle On is the default setting, and the Print button is lit.
Page 52 21/12/2009 Printing Procedure Auto Cycle Enabled Place the original Press the Master Making key Makes the master and the prints Operation Manual, Basics, Basic Procedure Very easy, but you cannot make trial prints or proof prints. Page 52...
Page 53 21/12/2009 Printing Procedure Auto Cycle Disabled Place the original Make sure that the master making key is lit, then press the Master Making key Makes the master and a trial print • The trial print primes the ink supply Then, press the Proof key (optional step) Makes a test print •...
Page 54: Auto Document Feeder
21/12/2009 Auto Document Feeder Up to 50 sheets, face-up Use Auto Cycle mode to allow non-stop copying Up to 50 originals can be placed in the feeder. Use the Auto Cycle feature to make sets of copies of more than one page. Otherwise, you will have to press the Print key for every original.
Page 55 21/12/2009 Adjusting the Image Position Forwards and Backwards Adjustment in both directions done at the operation panel This changes the registration motor timing. No dials or levers to adjust Operation Manual, Basics, Sample Print and Adjustment There are two ways, both done with the image positioning keys. Shifting forward or backward: This alters the registration motor start timing and turns the pressure cylinder (which has the paper clamper attached to it).
Page 56 21/12/2009 Adjusting the Image Position Left and Right Side table adjustment dial This moves the paper feed table to the left or right. In the diagram, the image is moved to the right. Page 56...
Page 57: Adjusting The Image Density
21/12/2009 Adjusting the Image Density After Making a Master: Before Making a Master: Not possible in this model. Image Density Key Operation Manual, Operation, Adjusting the Print Image Density In this model, if you adjust the printing speed, the machine automatically adjusts the printing pressure to keep a constant image density on the printout.
Page 58: Tint Mode
21/12/2009 Tint Mode Converts black to grey Required for the Japanese market This converts all black areas of the original to grey. This is a requirement for the Japanese market, for cultural reasons (certain events, such as funerals, require the use of grey instead of black). Page 58...
Page 59 21/12/2009 Adjusting the Printing Speed 60, 75, 90, 105, or 120 sheets/minute When you use A3, 11" × 17" and 209.3 g/m2 , 55.6 lb paper, slow the printing speed down to Setting 1, 2 or 3. Default: 90 Note the five possible speeds. A lower speed applies more ink to the paper.
Page 60: Selecting The Original Type
21/12/2009 Selecting the Original Type Photo, Text, Text/Photo, Pencil Press this to change the original type. Then select with the arrow keys Operation Manual, Operation, Type of Original Note the four possible modes. For originals with letter and photo areas, letter/photo mode can be used. Page 60...
Page 61 21/12/2009 FEATURES This explains some of the features that are available with this machine. Page 61...
Page 62: Preset Reduce/Enlarge
21/12/2009 Preset Reduce/Enlarge Reduction: 4 settings Enlargement: 3 settings Note the fixed reproduction ratios available for this machine. There is no way to customize this with alternative ratios. The leading edge does not shift, but the centre does shift (see the top right drawing on the slide).
Page 63: Edge Erase
21/12/2009 Edge Erase Edge erase only No Centre Erase Erasing the border is useful when tidying up copies of book originals. The default margins can be adjusted using user tools. There is no Centre Erase feature. Page 63...
Page 64 21/12/2009 Thick and Thin Paper This lever controls the paper feed pressure. A decal on the machine shows the correct position for the lever for each paper type. There is more about this lever in the Paper Feed scetion. Page 64...
Page 65: Economy Mode
21/12/2009 Economy Mode Reduced thermal head energy Makes smaller holes in the master, so less ink is used This uses less ink, so the prints will be lighter. Page 65...
Page 66 21/12/2009 Class Modes Use the Class Settings to make different numbers of prints from the same original. You can also make the same number of prints from more than one original. This feature is useful for teachers who frequently make multiple print sets (notes, handouts, tests, etc) for their classes.
Page 67 21/12/2009 Class Modes Class /Year Makes prints from the same originals for all registered classes and years. This mode allows you to store the number of students in each class in the machine's memory before-hand. Memory Mode Normal memory mode: From a multi-page original, make a different number of copies of each original Stack memory mode: From a single page, make some stacks with a different number of copies in each stack...
Page 68: Combine Two Originals
21/12/2009 Combine Two Originals Prints two originals on one page Press the indicated button, then select ‘Combine 2’. The feature is not cancelled at the end of the job. This could be a problem. To make sure that the feature is cancelled at the end of the job, change the setting of the following user tool to ‘Cancel’: Mode Setting –...
Page 69 21/12/2009 Repeat This prints two copies of the original on one sheet of copy paper. You cannot use the ADF for this function. Press the indicated button, then select ‘Repeat 2’. The feature is not cancelled at the end of the job. This could be a problem.
Page 70 21/12/2009 Skip Feed Makes the drum turn a few times between prints This lets the ink on the last print dry before the next is delivered Operation manual, Operation, Skip Feed Use this if ink is making the back sides of prints dirty. The drum will rotate one or more extra times between pages, giving the user the chance to remove the prints one by one (a larger number of drum rotations also allows the ink to dry).
Page 71 21/12/2009 Programs Up to 9 programs of frequently used settings can be stored. Page 71...
Page 72: Security Mode
21/12/2009 Security Mode Prevents other users from making prints with your master This prevents others from making prints using the master that you left on the drum. Normally, the user can walk up to the machine and make prints of the master that happens to be on the drum.
Page 73 21/12/2009 Security Mode After Security mode is set: You cannot press the {Proof} key or the {Print} key You cannot pull out the drum unit. Security mode cannot be cleared by turning off the main switch. Security mode will be cancelled when you set a new original and press the {Master Making} key.
Page 74: User Codes
21/12/2009 User Codes There are some three-digit codes that can be allocated to authorized users. See the operation manual for a list of these codes. Allocate one to each authorized user. To use this feature, turn it on with a user tool: User Tools –...
Page 75: Quality Start
21/12/2009 Quality Start If the machine is not used for a long time, or when you change to a drum that has not been used recently, the ink on the drum may dry up. This might affect the print quality. To solve this problem, you can have the machine carry out a few idle spins of the drum before a print run.
Page 76 21/12/2009 Auto Quality Start You can program the machine to automatically carry out idle spins. This is called Auto Quality Start. To use this function, you must turn it on with a user tool: Mode Setting – Setting Q.Mode You can specify the number of idle spins according to the length of time that the machine was not used: User Tools - Mode Setting –No.
Page 77 21/12/2009 Colour Drum Use a separate drum for each colour. Several colours of ink are available. A range of coloured inks are available. You need a separate drum for each colour. To make multicoloured copies, you have to prepare a separate original for each colour Page 77...
Page 78 21/12/2009 USER TOOLS AND SP MODES Page 78...
Page 79: User Tools
21/12/2009 User Tools Operation Manual, User Tools, Accessing the User Tools Make sure that the trainees know how to enter user tools mode. Page 79...
Page 80: Energy Saver Modes
21/12/2009 Energy Saver Modes You can select one of two modes: Energy Saver Mode • The display goes off. • Printing from a computer is possible. • To operate the machine, press the operation switch, or place originals on the exposure glass or in the ADF. Auto Off Mode •...
Page 81 21/12/2009 Energy Saver Modes To select either Energy Saver or Auto Off mode: User Tools – System Settings – Mode Setting – Energy Saver Option The machine will go into the selected mode after this timer runs out User Tools – System Settings – Timer Setting – Energy Saver Timer Default: 3 minutes You can also switch the machine off automatically at...
Page 82: Administrator Tools
21/12/2009 Administrator Tools User Tools – System Settings – Administrator Tools Machine use can be monitored with user codes. There is no key operator code. Windows Authentication and other security functions are not used. Page 82...
Page 83 21/12/2009 User Tools System Settings – Set Operation Mode Min Quantity, Max Quantity: These let you put minimum and maximum limits on the number of prints per original Class Display: For companies and other organizations, the “Class/Year” format may be inappropriate.
Page 84 21/12/2009 User Tools System Settings – Mode Settings Ignore Paper Size: If you are making prints on custom size paper and the original image does not entirely appear on the print, select “Ignore”. The machine will not detect the paper length. No Orig Size (ADF): Use this if you are using non- standard original sizes in the ADF.
Page 85 21/12/2009 User Tools System Settings – Administrator Tools Set User Code : User codes. Off/on Restricted Access: If set to ‘On’, a key counter must be inserted to use the machine. Page 85...
Page 86 21/12/2009 SP Modes 1 2-1: Default print speed 2-2: Default image position 2-22: Double count-up for master and print counters if A3 is used 2-60: Makes outlines of vector images 6-27 to 6-30: Master making density (for various original modes) Have the class try out various settings to see the effects.
Page 87: Troubleshooting
21/12/2009 TROUBLESHOOTING Page 87...
Page 88 21/12/2009 Replenishing Supplies and Troubleshooting Study the procedures in the Operation Manual. Operation Manual, Replenishing Supplies/Troubleshooting Have the trainees look through these sections of the operation manual. They must be familiar with all the covers and levers etc that are used to replenish supplies, clear jams, and so on.
Page 89 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE OPERATION This part of the course will deal with general operation and copying. Teach and demonstrate procedures from the operation manuals. Select the items to be taught in the class in accordance with the experience level of the trainees.
Page 90 21/12/2009 COMPONENTS This section explains the machine’s components from the user’s point of view. Page 90...
Page 91 21/12/2009 Machine Exterior Operation Manual, Machine Exterior Go over the major components of the machine from the user’s point of view. Be sure that the class understand the following components 4. Master tray: Open here to replace the master roll 5.
Page 92 21/12/2009 Machine Interior Operation Manual, Machine Interior Go over this briefly. The document feeder is an option. Be sure that the class understand the following components 3. Paper alignment wings: Lift or lower the wings according to the type of paper used, to stack the paper neatly.
Page 93 21/12/2009 Operation Panel Operation Manual, Control Panel Keys Make sure that the class are familiar with the operation panel keys. There may be some keys that are not be familiar to photocopier technicians. These keys are used to access the various features of this machine. The features will be mentioned later in this section.
Page 94 21/12/2009 Indicators Operation Manual, Control Panel Indicators Make sure that the class are familiar with the operation panel indicators. Be sure that the class understand the following items. 1. Special feature indicator: Lets you know when one or more of the keys under the cover at the left of the operation panel (item 12) has been selected.
Page 95: Preparing To Print
21/12/2009 PREPARING TO PRINT This section explains some basic points about originals and copy paper, and how to set up the machine. Page 95...
Page 96 21/12/2009 Originals Note that some types of originals may not be detected properly. Originals should not have dark areas or bold characters right at the leading edge, or the prints may have dirty edges. Note that there is a 5 mm margin at the leading edge of the original and a 2 mm margin at the trailing edge which will not be copied, even if the original is positioned correctly.
Page 97 21/12/2009 Notes Concerning A3 If you use an A3 original, use a reproduction ratio to reduce the image size, to make sure that you get all of the image on the copy paper. When you use A3, 11" × 17" and 209.3 g/m2 , 55.6 lb paper, slow the printing speed down to Setting 1, 2 or 3.
Page 98 21/12/2009 Dealing with Paper Curl Operation Manual, Operation, Print Paper Printing Paper Note the recommended sizes and types of paper. Page 98...
Page 99 21/12/2009 Paper Feed Table Lock Lever Side Fences Operation Manual, Operation, Printing Preparations Note the correct way to set up the feed table. Raise the lock lever before you move the side fences. Then lock the side fences after you add paper. Page 99...
Page 100 21/12/2009 Paper Delivery Table Overview These items can be adjusted. Side and end plates: Move these to the correct paper size Paper alignment wings Chocks (buffer fins) These items must be adjusted manually. Page 100...
Page 101 21/12/2009 Paper Delivery Table Adjustments Chocks Buffer Fins Paper Alignment Wings Three settings: Up, Down, 45 degrees Operation Manual, Operation, Printing Preparations Note the correct way to set up the delivery table. In this machine, the side and end fences are not the only items to adjust. The paper alignment wings and chocks must be adjusted to match the paper size and thickness.
Page 102 21/12/2009 Paper Delivery Table Recommended Settings This table, from the operation manual, shows the recommended settings for each paper type. Page 102...
Page 103 21/12/2009 Folding up the Paper Feed and Paper Delivery Tables Study the correct procedures in the operation manual, to prevent damage to the machine. Operation Manual, Operation, After Printing Page 103...
Page 104: Basic Printing Procedure
21/12/2009 BASIC PRINTING PROCEDURE This explains the basic procedure for how to make copies. Page 104...
Page 105 21/12/2009 Auto Cycle On or Off The basic printing procedure depends on whether Auto Cycle is on or off. Go on to the next slide. Page 105...
Page 106 21/12/2009 Auto Cycle Auto Cycle Faster copying of a series of originals No pause between originals, so no proof copies can be made Default: On (User Tools – System Settings – Mode Setting – Auto Cycle) Auto Cycle allows faster copying of a series of originals. Auto Cycle On is the default setting, and the Print button is lit.
Page 107 21/12/2009 Printing Procedure Auto Cycle Enabled Place the original Press the Master Making key Makes the master and the prints Operation Manual, Basics, Basic Procedure Very easy, but you cannot make trial prints or proof prints. Page 107...
Page 108 21/12/2009 Printing Procedure Auto Cycle Disabled Place the original Make sure that the master making key is lit, then press the Master Making key Makes the master and a trial print • The trial print primes the ink supply Then, press the Proof key (optional step) Makes a test print •...
Page 109 21/12/2009 Auto Document Feeder Up to 50 sheets, face-up Use Auto Cycle mode to allow non-stop copying Up to 50 originals can be placed in the feeder. Use the Auto Cycle feature to make sets of copies of more than one page. Otherwise, you will have to press the Print key for every original.
Page 110 21/12/2009 Adjusting the Image Position Forwards and Backwards Adjustment in both directions done at the operation panel This changes the registration motor timing. No dials or levers to adjust Operation Manual, Basics, Sample Print and Adjustment There are two ways, both done with the image positioning keys. Shifting forward or backward: This alters the registration motor start timing and turns the pressure cylinder (which has the paper clamper attached to it).
Page 111 21/12/2009 Adjusting the Image Position Left and Right Side table adjustment dial This moves the paper feed table to the left or right. In the diagram, the image is moved to the right. Page 111...
Page 112 21/12/2009 Adjusting the Image Density After Making a Master: Before Making a Master: Not possible in this model. Image Density Key Operation Manual, Operation, Adjusting the Print Image Density In this model, if you adjust the printing speed, the machine automatically adjusts the printing pressure to keep a constant image density on the printout.
Page 113 21/12/2009 Tint Mode Converts black to grey Required for the Japanese market This converts all black areas of the original to grey. This is a requirement for the Japanese market, for cultural reasons (certain events, such as funerals, require the use of grey instead of black). Page 113...
Page 114 21/12/2009 Adjusting the Printing Speed 60, 75, 90, 105, or 120 sheets/minute When you use A3, 11" × 17" and 209.3 g/m2 , 55.6 lb paper, slow the printing speed down to Setting 1, 2 or 3. Default: 90 Note the five possible speeds. A lower speed applies more ink to the paper.
Page 115 21/12/2009 Selecting the Original Type Photo, Text, Text/Photo, Pencil Press this to change the original type. Then select with the arrow keys Operation Manual, Operation, Type of Original Note the four possible modes. For originals with letter and photo areas, letter/photo mode can be used. Page 115...
Page 116 21/12/2009 FEATURES This explains some of the features that are available with this machine. Page 116...
Page 117 21/12/2009 Preset Reduce/Enlarge Reduction: 4 settings Enlargement: 3 settings Note the fixed reproduction ratios available for this machine. There is no way to customize this with alternative ratios. The leading edge does not shift, but the centre does shift (see the top right drawing on the slide).
Page 118 21/12/2009 Edge Erase Edge erase only No Centre Erase Erasing the border is useful when tidying up copies of book originals. The default margins can be adjusted using user tools. There is no Centre Erase feature. Page 118...
Page 119 21/12/2009 Thick and Thin Paper This lever controls the paper feed pressure. A decal on the machine shows the correct position for the lever for each paper type. There is more about this lever in the Paper Feed scetion. Page 119...
Page 120 21/12/2009 Economy Mode Reduced thermal head energy Makes smaller holes in the master, so less ink is used This uses less ink, so the prints will be lighter. Page 120...
Page 121 21/12/2009 Class Modes Use the Class Settings to make different numbers of prints from the same original. You can also make the same number of prints from more than one original. This feature is useful for teachers who frequently make multiple print sets (notes, handouts, tests, etc) for their classes.
Page 122 21/12/2009 Class Modes Class /Year Makes prints from the same originals for all registered classes and years. This mode allows you to store the number of students in each class in the machine's memory before-hand. Memory Mode Normal memory mode: From a multi-page original, make a different number of copies of each original Stack memory mode: From a single page, make some stacks with a different number of copies in each stack...
Page 123 21/12/2009 Combine Two Originals Prints two originals on one page Press the indicated button, then select ‘Combine 2’. The feature is not cancelled at the end of the job. This could be a problem. To make sure that the feature is cancelled at the end of the job, change the setting of the following user tool to ‘Cancel’: Mode Setting –...
Page 124 21/12/2009 Repeat This prints two copies of the original on one sheet of copy paper. You cannot use the ADF for this function. Press the indicated button, then select ‘Repeat 2’. The feature is not cancelled at the end of the job. This could be a problem.
Page 125 21/12/2009 Skip Feed Makes the drum turn a few times between prints This lets the ink on the last print dry before the next is delivered Operation manual, Operation, Skip Feed Use this if ink is making the back sides of prints dirty. The drum will rotate one or more extra times between pages, giving the user the chance to remove the prints one by one (a larger number of drum rotations also allows the ink to dry).
Page 126 21/12/2009 Programs Up to 9 programs of frequently used settings can be stored. Page 126...
Page 127: Security Mode
21/12/2009 Security Mode Prevents other users from making prints with your master This prevents others from making prints using the master that you left on the drum. Normally, the user can walk up to the machine and make prints of the master that happens to be on the drum.
Page 128 21/12/2009 Security Mode After Security mode is set: You cannot press the {Proof} key or the {Print} key You cannot pull out the drum unit. Security mode cannot be cleared by turning off the main switch. Security mode will be cancelled when you set a new original and press the {Master Making} key.
Page 129 21/12/2009 User Codes There are some three-digit codes that can be allocated to authorized users. See the operation manual for a list of these codes. Allocate one to each authorized user. To use this feature, turn it on with a user tool: User Tools –...
Page 130 21/12/2009 Quality Start If the machine is not used for a long time, or when you change to a drum that has not been used recently, the ink on the drum may dry up. This might affect the print quality. To solve this problem, you can have the machine carry out a few idle spins of the drum before a print run.
Page 131 21/12/2009 Auto Quality Start You can program the machine to automatically carry out idle spins. This is called Auto Quality Start. To use this function, you must turn it on with a user tool: Mode Setting – Setting Q.Mode You can specify the number of idle spins according to the length of time that the machine was not used: User Tools - Mode Setting –No.
Page 132 21/12/2009 Colour Drum Use a separate drum for each colour. Several colours of ink are available. A range of coloured inks are available. You need a separate drum for each colour. To make multicoloured copies, you have to prepare a separate original for each colour Page 132...
Page 133 21/12/2009 USER TOOLS AND SP MODES Page 133...
Page 134: User Tools
21/12/2009 User Tools Operation Manual, User Tools, Accessing the User Tools Make sure that the trainees know how to enter user tools mode. Page 134...
Page 135: Energy Saver Modes
21/12/2009 Energy Saver Modes You can select one of two modes: Energy Saver Mode • The display goes off. • Printing from a computer is possible. • To operate the machine, press the operation switch, or place originals on the exposure glass or in the ADF. Auto Off Mode •...
Page 136 21/12/2009 Energy Saver Modes To select either Energy Saver or Auto Off mode: User Tools – System Settings – Mode Setting – Energy Saver Option The machine will go into the selected mode after this timer runs out User Tools – System Settings – Timer Setting – Energy Saver Timer Default: 3 minutes You can also switch the machine off automatically at...
Page 137 21/12/2009 Administrator Tools User Tools – System Settings – Administrator Tools Machine use can be monitored with user codes. There is no key operator code. Windows Authentication and other security functions are not used. Page 137...
Page 138 21/12/2009 User Tools System Settings – Set Operation Mode Min Quantity, Max Quantity: These let you put minimum and maximum limits on the number of prints per original Class Display: For companies and other organizations, the “Class/Year” format may be inappropriate.
Page 139 21/12/2009 User Tools System Settings – Mode Settings Ignore Paper Size: If you are making prints on custom size paper and the original image does not entirely appear on the print, select “Ignore”. The machine will not detect the paper length. No Orig Size (ADF): Use this if you are using non- standard original sizes in the ADF.
Page 140 21/12/2009 User Tools System Settings – Administrator Tools Set User Code : User codes. Off/on Restricted Access: If set to ‘On’, a key counter must be inserted to use the machine. Page 140...
Page 141 21/12/2009 SP Modes 1 2-1: Default print speed 2-2: Default image position 2-22: Double count-up for master and print counters if A3 is used 2-60: Makes outlines of vector images 6-27 to 6-30: Master making density (for various original modes) Have the class try out various settings to see the effects.
Page 142: Troubleshooting
21/12/2009 TROUBLESHOOTING Page 142...
Page 143 21/12/2009 Replenishing Supplies and Troubleshooting Study the procedures in the Operation Manual. Operation Manual, Replenishing Supplies/Troubleshooting Have the trainees look through these sections of the operation manual. They must be familiar with all the covers and levers etc that are used to replenish supplies, clear jams, and so on.
Page 144 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE MACHINE OVERVIEW Page 144...
Page 145: Printing Process
21/12/2009 Printing Process Drum Master Eject Box Thermal Head Paper Delivery Master Press Roller Table Buffer Outline the printing process. Point out the following: First, the used master still wrapped round the drum is ejected and fed into the eject box.
Page 146: Electrical Components
21/12/2009 Electrical Components Study the electrical component layout, the point-to- point diagram, and the component descriptions list. Make sure that you can find the components on the diagrams and in the machine. Introduce the point-to-point and electrical component layout diagrams. Go through the electrical component list in the service manual.
Page 147: Drive Layout
21/12/2009 Drive Layout Master Feed Motor Pressure Plate Motor Thermal Head Clamper Drive Motor Motor Duct Plate Motor Paper Delivery Table Motor Motor Printing Paper Feed Registration Main Pressure Motor Motor Motor Motor Service Manual, section 6.1.3 Demonstrate the major drive paths in the machine. Main motor –...
Page 148: Pcb Replacement
21/12/2009 PCB Replacement MPU Board After you replace the board: • Remove the RAM from the old board and put it on the new board • Adjust the sensors – Duct jam sensor – Master edge sensor – 2 drum master sensor –...
Page 149 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE SCANNER The document feeder is an optional peripheral. It will be described in a separate section of the course. Page 149...
Page 150 21/12/2009 Overview ADF Exposure Glass Main Exposure Glass Xenon Lamp A xenon lamp illuminates the original. A CCD receives the light reflected from the original. Service Manual, section 6.3.1 The exposure lamp is a xenon lamp. Light reflected from the original is reflected onto a CCD. Page 150...
Page 151: Scanner Drive
21/12/2009 Scanner Drive Home Position Sensor Scanner Drive Motor The scanner drive motor drives the scanner. In book mode, the scanner moves down the page. In ADF mode, the scanners stay at home position. The scanner drive motor (a stepper motor) drives the scanner. Book Mode The scanner motor moves the scanner down the exposure glass.
Page 152 21/12/2009 Original Size Detection (Platen Mode) There is no original size detection. Page 152...
Page 153 21/12/2009 Size Detection Timing Platen Platen cover - When the platen cover sensor is activated Optional ADF - When the DF position sensor is activated Covers open - When the Start key is pressed The slide explains the timing for reading the sensors (if they are being used). The sensors are read when the platen has been closed to about 15 cm above the exposure glass.
Page 154: Service Remarks
21/12/2009 Service Remarks Do not touch the xenon lamp while it is on. Calibrate the SBU (SP 6-31) if the MPU RAM or white plate is replaced. Do this with the other image adjustments, after you replace the RAM on the MPU board, or after you replace the white plate above the exposure glass.
Page 155 21/12/2009 Replacement Do the procedures in section 3.3 of the service manual. Page 155...
Page 156: Image Processing
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE IMAGE PROCESSING This section gives a brief outline of image processing. There are very few adjustments for the technician in this model. Because of this, detailed questions from the class should not be encouraged; a detailed description of image processing techniques will not be provided in this instructors guide.
Page 157 21/12/2009 Overview Service Manual, section 6.4.1 Image processing is done by the ECU board. The SBU sends 8-bit digital data to the MPU board. The A/D conversion circuits inside the SBU convert the analog input from the CCD into 8-bit digital data. The CCD is 600 dpi.
Page 158: Original Types
21/12/2009 Original Types There are four basic original types Text Photo Text/Photo Pencil The image processing that is used depends on the selected original type. Page 158...
Page 159 21/12/2009 Auto Background Correction 0.5mm 10mm 75mm 75 mm Sub scan direction Platen Prevents the original’s background from appearing on copies Disabled by default (enable with user tool User Tools – Mode Setting – Background on/off) This process prevents background from appearing on copies. The machine takes peak white data taken from the indicated locations while the scanner moves down the page.
Page 160: Auto Shading
21/12/2009 Auto Shading Corrects the image signal for CCD and scanner irregularities Done at the start of each page. The white level correction compensates for: Loss of brightness towards the ends of the exposure lamp Variations in sensitivity among elements of the CCD Distortions in the light path The black level correction compensates for: Variations in response to the dummy black pixels with time...
Page 161 21/12/2009 Filtering Emphasizes sharpness. The filter can be adjusted to make lines sharper in either the main scan or sub scan direction. To adjust the strength of the filter, use SP 6-32 to 37. There are adjustments for each original type Used with Letter, Letter/Photo, and Photo.
Page 162: Thermal Head
21/12/2009 Thermal Head Writes the processed image data on the master Resolution: 400 dpi Power: Comes from the PSU Overheat protection: Thermistor Can be damaged if used when humidity is high Service Manual, section 6.4.5 The processed image data is printed by the thermal head, to produce a master. This machine uses a 400 dpi thermal head.
Page 163 21/12/2009 Thermal Head Energy The temperature in the drum has an effect on the thermal head energy. This can be disabled with SP 2-39 (for black ink), SP 2-40 (colour ink), or 2-43 (A4 drum). There is a thermistor in the drum to measure the temperature.
Page 164 21/12/2009 SP Modes 2-60: Bold text for letter mode, on/off 6-27 to 6-30: Master making density with the various original type settings 6-31: SBU calibration Do this with the other image adjustments, after you replace the MPU RAM, or after you replace the white plate above the exposure glass.
Page 165: Image Adjustment
21/12/2009 Image Adjustment If you must adjust the image position on the prints, do the image adjustments in the order that is given in the service manual. Service manual, section 5.7.3 If you replace the RAM on the MPU board (or if you install a new MPU and do not use the RAM from the old board), you must do these image adjustments.
Page 166 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE MASTER EJECTION Page 166...
Page 167 21/12/2009 Overview Pressure Master Eject Clamper Plate Rollers Drum Master Sensor The previous master remains on the drum to prevent ink on the drum surface from drying. The eject mechanism opens the master clamper and removes the previous master from the drum. Service Manual, section 6.2.1 After printing, the used master remains on the drum to prevent ink drying on the drum.
Page 168 21/12/2009 Master Clamper Opening Drum Master Eject Guide Master eject position sensor Rollers Detects when the drum is Clamper at the eject position Open Clamper motor Sensor Opens the clamper Clamper open and close sensors Monitor the clamper Drum guide Holds the drum at the eject position while clamper is open...
Page 169: Master Eject Rollers
21/12/2009 Master Eject Rollers Master Eject Rollers Master Eject Sensor Master Eject Motor The master eject motor drives these rollers. After the master has been pulled off, the drum turns to the master feed position, then stops. The master eject sensor checks for jams Service Manual, section 6.2.3 An independent motor drives these rollers.
Page 170 21/12/2009 Master Eject Box Pressure Plate Pressure plate Pushes the used master into the eject Pressure plate motor Moves the plate until the limit sensor is activated Pressure plate limit sensor Detects when the master has been compressed enough Pressure If the sensor is not actuated within a set Plate Motor...
Page 171 21/12/2009 Replacement Master eject unit (service manual, section 3.4) Have the class remove and replace the parts on the slide. Page 171...
Page 172 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE MASTER FEED Page 172...
Page 173 21/12/2009 Overview Platen Roller Cutter Clamper Duct The platen roller feeds the new master to the drum. Before the previous master is ejected, the new master is stored in the master buffer duct. After the previous master is ejected, the drum turns to the master feed position.
Page 174 21/12/2009 Automatic Master Set Positioning Overview The machine automatically moves the leading edge of the master to the correct position. The master feed motor and master edge sensor are used for this process. The leading edge is not cut. The next few slides explain the mechanism. Page 174...
Page 175 21/12/2009 Automatic Master Set Positioning - 1 The duct plate opens and the master vacuum fans turn on. If the master edge sensor detects the Edge Sensor: master, the Does not detect master master feed Duct motor does not Plate start.
Page 176 21/12/2009 Automatic Master Set Positioning - 2 Then the motor Edge Sensor: reverses until the Detects leading edge edge sensor detects the leading edge of the master. The master is now at the correct position. Page 176...
Page 177 21/12/2009 Automatic Master Set Positioning - 3 Duct Plate Then, the duct plate goes back to the middle position. The duct plate has four positions. We will see these later. Page 177...
Page 178 21/12/2009 Thermal Head Up/Down Movement Thermal Head HP Sensor Thermal Head Drive Motor Platen Roller Thermal Head The thermal head only contacts the platen roller during master making. Before the master is made, the thermal head drive motor moves the thermal head up against the platen roller.
Page 179 21/12/2009 Master Buffer - 1 Blower Fan Clamper Master Vacuum Fans Before the previous master is fully ejected, three master vacuum fans suck the new master into the duct. The blower fan keeps the folds of the master separated in the duct. After the drum gets to the master making position, the master is fed from the duct until the clamper catches the leading edge of the master.
Page 180 21/12/2009 Master Buffer - 2 Duct Jam Sensor Duct Then the drum starts to turn and the new master is pulled out of the duct. The duct jam sensor detects if the master gets stuck in the duct. Page 180...
Page 181 21/12/2009 Master Duct Jam Removal Open the lower master tray and remove the jammed master. Page 181...
Page 182 21/12/2009 Duct Plate Mechanism - Drive Duct Plate Duct Plate Motor Duct Plate The duct plate motor moves the duct plate. HP Sensor The duct plate has four stopping positions. The duct plate HP sensor detects when the duct plate is open Four positions –...
Page 183 21/12/2009 Duct Plate Mechanism – Four Positions Open Closed Duct Plate Middle Position Master Push Mylar Application The master push mylar makes sure that the master contacts the drum properly all across its width, and this makes sure that ink is distributed through the master correctly.
Page 184 21/12/2009 Duct Plate Operation Procedure - 1 Master Tension Roller Master Duct Plate Clamper (Middle Position) Before printing, the duct plate is in the middle position. When the master is fed, the duct plate closes. The master tension roller catches the leading edge of the master.
Page 185 21/12/2009 Duct Plate Operation Procedure - 2 Cutter Master Push Mylar Duct Drum Rotates When the master clamper opens, the duct plate goes to the open position. The master is fed into the duct. When the drum starts to rotate, the duct goes to the ‘master push mylar application’...
Page 186: Master Feed
21/12/2009 Master Feed Platen Roller Master Feed The master feed Roller motor drives the platen roller and the master feed roller. The drum turns at 15 rpm. The tension roller prevents creases in the master during Master Feed wrapping around the Motor drum.
Page 187 21/12/2009 Master Clamper Opening Tension Roller Clamper motor Opens the clamper Tension roller Pushed away from the guide plate when the clamper opens Clamper Motor Service Manual, section 6.5.8 When the clamper opens, the tension roller in the master feed unit is pushed out of the way.
Page 188 21/12/2009 Master Push Mylar Duct Plate Motor Mylar The duct plate motor pushes the mylar into contact with the master to flaten it against the surface of the drum. This makes sure that ink is applied correctly through the master. The motor moves the duct plate to the ‘mylar application position’.
Page 189 21/12/2009 Drum Master Sensor Black Sensor Patches There are black patches on the clamper and on the drum. If the sensor detects a black patch, then there is no master on the drum, and the master push mylar will not be applied to the drum. Page 189...
Page 190 21/12/2009 Cutter Home Position Two cutter blades Sensor Cut the master as the cutter moves towards the rear of the machine Cutter motor Only turns one way, but the double-spiral shaft returns the cutter to the front Home position sensor Detects when the cutter has returned to the front...
Page 191 21/12/2009 Re-cutting If the CPU cannot detect a signal from the master eject position sensor signal within 5.0 seconds after the main motor turns on at the start of master making, this could be because of an error in master cutting.
Page 192: Jam Detection
21/12/2009 Jam Detection Drum Master Sensor The drum master sensor checks for a jam when the drum is at the master eject position. Service Manual, section 6.5.10 There are no sensors in the master feed path. The drum master sensor checks for a master feed jam after master making. If the sensor cannot detect the black patch on the clamper, it means that a master is covering it.
Page 193: Service Remarks
21/12/2009 Service Remarks Do not touch the thermal head elements with bare hands (clean with alcohol). Remove foreign materials from the platen roller and master roll area. Do not touch the master surface with bare hands Do not touch the connector terminals with bare hands.
Page 194 21/12/2009 SP Modes 6-60: Master return value The auto adjustable master set mechanism automatically moves the leading edge of the master to the correct position after the user installs a master roll. This position can be adjusted with SP 6-60. This SP adjusts the amount that the machine feeds the master after it detects the leading edge of the master.
Page 195 21/12/2009 Replacement and Adjustment Thermal Head Thermal head replacement You must release the thermal head with SP 5-74. If you do not do this, you cannot remove the thermal head. After you install a new thermal head, you must do the thermal head voltage adjustment Thermal head voltage adjustment This must be done every time the thermal head or...
Page 196 21/12/2009 Replacement and Adjustment Thermal Head Voltage Adjustment Connect the oscilloscope Connect the positive terminal to TP701. Connect the negative terminal to TP702. Do not short the two terminals. Select SP 5-12 and press Start. Turn VR1 slowly, until the output voltage is the same as the value on the decal.
Page 197 21/12/2009 Replacement and Adjustment Sensor Adjustments Adjust these sensors after you change the MPU. Duct jam sensor Master edge sensor drum master sensor Master end sensor Service Manual, section 3.5.6 to 3.5.9 Sensor Adjustments Do these every time the MPU has been changed. This adjustment must be done even if the old RAM is placed on the new board.
Page 198: Replacement And Adjustment
21/12/2009 Replacement and Adjustment Do the procedures in section 3.5 of the service manual. Service Manual, section 3.5.1. to 3.5.5 Page 198...
Page 199 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE DRUM This section describes the drum, including ink supply. Page 199...
Page 200 21/12/2009 Overview Metal Screen Cloth Screen Drum Idling Ink Roller Roller Doctor Roller Two screens: metal screen, cloth screen Ink supply mechanism inside the drum Service Manual, section 6.6.1 Go over the basic points in the manual. Page 200...
Page 201: Drum Drive
21/12/2009 Drum Drive Master Eject Position Sensor Driven by the main motor Only turns clockwise Two stopping positions: master eject position, master feed position Master eject position: Detected using the main motor encoder and the master eject position sensor Feed Start Master feed position: Sensor Detected using the feed...
Page 202: Ink Supply
21/12/2009 Ink Supply Ink Roller Ink Pump Motor The ink pump is outside the drum. The ink pump motor drives the gears and piston that pumps the ink. Ink comes out onto the ink roller through 4 openings in the ink distributor.
Page 203 21/12/2009 Drum Idling Roller Idling Roller Motor The drum idling roller puts ink on the ink roller before and after printing. Drum speed during idling: 30 This makes sure that the first print has sufficient ink HP Sensor density, even if the machine is not used for a long time.
Page 204 21/12/2009 Ink Roller Ink Roller Doctor Roller Press Roller Doctor roller: Ensures even ink thickness on the ink roller. Ink roller drive gear: Prevents the ink roller from being reversed manually. Press roller: Presses the master against drum screen & ink roller. Ink goes through the holes in the drum and master to the paper.
Page 205: Ink Supply Control
21/12/2009 Ink Supply Control The ink detection pins detect the ink level. If the level is low, the ink supply motor turns on. If the level stays low for 30 seconds, the machine detects ink end. The ink roller blade removes ink at the edges of the roller.
Page 206 21/12/2009 Master Detection Black Patch (Clamper) Black Patch (Drum Screen) Drum Master Sensor Black patch on the drum: If a master covers this black patch, the machine detects that there is a master on the drum. If no master is detected, the master eject process is skipped.
Page 207 21/12/2009 Drum Home Position Detection The drum home position sensor detects when the drum is at home position. Then, the green LED lights. This green light tells the user that the drum can be removed. If the red light is lit, the drum cannot be removed.
Page 208: Service Remarks
21/12/2009 Service Remarks Make sure that the main motor pulley is put back in the correct position. Do not adjust the doctor roller gap. Make sure the drum master clamper springs are put back properly. Do not get ink on the inner surface of the clamping plate.
Page 209 21/12/2009 Replacement Do the procedures in section 3.8 of the service manual. Drum cloth screen Drum master clamper Drum metal screen Ink roller unit Idling roller motor Before you start these procedures: Remove the ink around the ink roller. To do this, set SP2-10 (ink detection) to OFF, and feed paper until ink ends.
Page 210 21/12/2009 Drum Master Sensor A VR was added for this sensor. Do not use it in the field. It is for factory use only. Page 210...
Page 211 21/12/2009 Adjustment Ink pump (plunger position) Ink detection Main motor pulley position Main drive timing belt tension Service Manual, section 3.8 Have the class try the adjustments on the slide. Doctor Roller Gap There is a procedure in the manual. However, do not try it in the field. Ink Pump Plunger Position Do this after replacing the ink pump.
Page 212 21/12/2009 SP Modes SP 2-28, 2-29, 2-38: Idling after printing Ensures that the first print has sufficient ink density if the machine was not used for a long time. Also, when the customer continuously prints small numbers (1 to 3 prints), ink leaks occur from the trailing edge of the drum.
Page 213 21/12/2009 SP Modes SP 2-34: Increases the image density of trial prints. This SP was added because trial print images are lighter than with other models. For details on this SP, see section 5.3.7 SP 2-100: Wraps a blank master around the drum. Useful when you remove a drum and keep it out of the machine for a long time.
Page 214: Paper Feed
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE PAPER FEED This section explains how paper is fed to the drum and how printing pressure is applied. Page 214...
Page 215 21/12/2009 Overview Feed Pick-up Roller Roller Registration Sensor Press Registration Friction Roller Roller The paper feed roller is driven by the paper feed motor. The registration roller is driven by the registration motor. If the registration sensor detects a non-feed, the machine tries to feed the paper again.
Page 216: Feed Mechanism
21/12/2009 Feed Mechanism Paper Feed Motor Guides The paper feed motor drives the pick-up and feed rollers. The motor turns on when the actuator on the drum turns on the feed start timing sensor. The guides help to feed paper that is not perfectly flat. Service Manual, section 6.7.2 Describe the mechanism.
Page 217 21/12/2009 Re-feeding If the registration sensor detects a non-feed, the machine tries again. However, if the machine detects a non-feed the second time, the jam indicator lights. This mechanism can cause registration errors of up to 5 mm. If the customer is not happy, you can disable re-feeding with SP 2-33.
Page 218 21/12/2009 Feed & Separation Pressure Pick-up Roller Pressure Pick-up roller pressure Separation The user can adjust with the lever. Pressure There are three positions (from left to right: thick paper, normal, thin paper) Separation pressure Technician adjustment only Service Manual, section 6.7.3 Describe these adjustments.
Page 219: Registration Roller Drive
21/12/2009 Registration Roller Drive Registration Motor The registration motor drives the lower roller. The motor speed depends on the printing speed selected by the user. The motor start timing depends on the image up/down shift position setting selected by the user. The motor stops when the paper reaches the press roller.
Page 220 21/12/2009 Registration Roller Up/Down The cam on the drum drive gear lifts the upper registration roller when the paper is between the drum and press roller. This prevents the registration rollers from interfering with paper feed by the drum and press roller. Service Manual, section 6.7.4, Registration Roller Up/Down Describe this briefly.
Page 221 21/12/2009 Printing Pressure Press Roller First, the front and rear pressure release solenoids release the press roller. But springs hold the press roller. The press roller is released when the drum rotates a bit more, and the high points of the cams on the flange at each end of the drum move away from the cam followers on...
Page 222 21/12/2009 Adjustable Printing Pressure The printing pressure motor automatically adjusts the printing pressure. The adjustment depends on the temperature and the selected printing speed. The pressure is applied through two springs. Press The printing pressure sensor detects the Roller amount of pressure Sensor that is applied.
Page 223 21/12/2009 Paper Table Paper Height Sensor Paper End Paper Table Sensor Motor The paper table motor lifts the paper table. The paper table stops when the paper height sensor is activated. The pick-up roller is lifted up by the top of the paper stack. When the height sensor turns off during paper feed, the table is lifted again.
Page 224 21/12/2009 Paper Table Lock Lever The lock lever holds the side fences in one place. The paper table shift dial moves the table from side to side. This moves the image from side to side. Dial Service Manual, section 6.7.7, Table side fences and side-to-side shift Describe the side fences and the lock lever.
Page 225 21/12/2009 Paper Table These friction pads are special service parts for customers who have problems with multiple feeds. Can be useful for thin paper These pads are not included in the accessories. Describe this briefly. It is normally used only for very thin paper. For normal types of paper, adjusting the feed and separation pressures should solve most feed problems.
Page 226 21/12/2009 Paper Table Paper Width Sensor Paper Length Sensor The width and length sensors detect the paper size. Service Manual, section 6.7.7, Table lifting/lowering Page 226...
Page 227 21/12/2009 Service Remarks Make sure that the friction pad base is put in the correct way around. Make sure that the paper feed and separation rollers are installed the correct way around. Do not touch the surfaces of the rollers with bare hands.
Page 228 21/12/2009 SP Modes 2-95: Paper table standby position If set to ‘high’, the paper table takes less time to go up from the standby position to the printing position. 6-20: Adjusts the amount of buckle at the registration roller, to correct skew during paper feed Normally not used.
Page 229 21/12/2009 Replacement Do the procedures in sections 3.6 and 3.7 of the service manual. Paper feed roller Pick-up roller Friction pad Paper width detection board Press roller Service Manual, sections 3.6 and 3.7 Have the class remove and replace the parts on the slide. Rollers and Friction Pad Make sure to install these parts the correct way around.
Page 230 21/12/2009 Adjustment Separation pressure Feed pressure: See the Operation section Press roller lock lever Printing pressure This is a mechanical adjustment for the basic printing pressure. The machine automatically adjusts this basic printing pressure for drum temperature and printing speed. There are also SPs to adjust the pressure if print density is not correct.
Page 231: Paper Delivery
21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE PAPER DELIVERY This section explains how paper is fed out of the machine to the delivery table. Page 231...
Page 232 21/12/2009 Overview Air Knife Exit Pawl Exit Sensor Delivery Table The exit pawl and air knife take the paper off the drum. There are three air knife fans. Also, there is an air pump to supply air through the exit pawl. The belt feeds the paper to the delivery table.
Page 233 21/12/2009 Drive The paper delivery motor drives the belts. The speed depends on the selected print speed. Motor A suction fan holds the paper against the belts. Service Manual, section 6.8.2 Describe this briefly. The main points are on the slide. Page 233...
Page 234: Air Knife
21/12/2009 Air Knife Exit Pawl Air Knife Fans x 3 The exit pawl and the air knife remove the paper from the drum. The air is supplied continuously throughout the job. The fans start when the print start key is pressed or after the cutter cuts the master.
Page 235 21/12/2009 Exit Pawl Air Pump Gear Pump The main motor drives this pump through the pump gear. Air from the pump goes out through a nozzle in the exit pawl. This air helps to separate the paper from the drum. Exit Pawl Service Manual, section 6.8.3 Page 235...
Page 236 21/12/2009 Exit Pawl Mechanism - 1 Clamper The pawl must be moved away when the master Exit Pawl clamper approaches it. The cam on the drum flange moves the exit pawl away. Exit Pawl Service Manual, section 6.8.4 When printing starts: The pawl moves near the drum when the printing pressure is applied (the pawl shaft is moved by press roller lifting mechanism, discussed earlier).
Page 237 21/12/2009 Exit Pawl Mechanism - 2 Printing Pressure Release Arm When the machine is not printing: The printing pressure release arm holds the pawl shaft down Service Manual, section 6.8.4 When printing is finished: The printing pressure release arm holds the exit pawl shaft down, so the pawl stays down even though the high point of the cam has moved away.
Page 238 21/12/2009 Delivery Table – Alignment Wings Change the angle by moving the guide manually. Helps to stack the paper more evenly on the table. Service Manual, section 6.8.5 Describe this briefly. The main points are on the slide. Do not confuse these paper alignment wings (on the paper delivery table; must be adjusted manually) with the paper delivery wings (inside the machine;...
Page 239 21/12/2009 Paper Delivery Table Plates The tabs (called ‘buffer fins’) on the inner sides of the plates catch the edges of the paper. Because of this, the paper falls more slowly onto the delivery table. This reduces ink stains on the rear sides and stacks the pages more evenly.
Page 240 21/12/2009 Replacement Do the procedures in section 3.9 of the service manual. Paper delivery unit Fan motor Service Manual, section 3.9 Have the class remove and replace the parts listed on the slide. Page 240...
Page 241 21/12/2009 Adjustment Exit pawl adjustment Clearance Drive timing Air pump alignment Service Manual, section 3.9 Have the class try these adjustments. Exit Pawl Adjustment The two parts of the exit pawl adjustment must be done in the order as shown on the slide.
Page 242 21/12/2009 SP Modes 2-37: Paper delivery motor speed Page 242...
Page 243 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE MAINTENANCE Page 243...
Page 244 21/12/2009 Two types of PM interval Based on time: 6 months is the basic interval Based on print count: 1.2 M prints is the basic interval There are no PM counters to reset. Service Manual, section 2 Draw the attention of the class to the maintenance table. There are two types of PM interval, as shown on the slide.
Page 245 21/12/2009 HP4-R2 TRAINING DUPLICATOR ENGINE TROUBLESHOOTING This section goes over the troubleshooting tools built into the machine. In the field, technicians will have to think for themselves and draw on their own experiences. However, the procedures in the manual will give some ideas for where to start to look when a particular problem occurs.
Page 246: Reset Procedures
21/12/2009 Reset Procedures SP 7-1: This resets all SP settings except for the following SP numbers. SP2-20: Destination settings SP3-01: Present time SP6-xx: Adjustments Page 246...
Page 247 21/12/2009 SP Modes - Tests 2-11 to 2-15: Switches sensors on/off 4-xx: Input tests 5-xx: Output tests 6-50 to 6-53: Displays the output voltages from sensors. Used to adjust the sensors. 8-10: Test pattern printout 8-19: ADF test 8-20: Scanner free run 8-21: Paper feed at 15 rpm (with paper) 8-22: Paper feed at 15 rpm (without paper) 8-30: Operation panel test...
Page 248 21/12/2009 SP Modes - Counters 1-1: Total master counter 1-20: Total print counter 7-3: Clears the total counters 1-50 to 1-61: Jam counters 7-4: Clear the jam and error counters Page 248...
Page 249 21/12/2009 SP Modes - Others 1-72: Displays the machine serial number 1-80: Displays the error code history (the last 40 error codes) 1-81: Displays the service telephone number Page 249...
Page 250 21/12/2009 HP4-R2 TRAINING OPTIONAL DOCUMENT FEEDER PURPOSE OF THIS SECTION The mechanisms in the optional document feeder will be described. This option does not have a reversing mechanism. The document feeder is the same as the one used with the Sapphire 2. If all the class members are familiar with this device, you can skip this part of the class.
Page 251 21/12/2009 Overview Feeds originals past the DF exposure glass while scanning No inverter unit The DF exposure glass is a narrow glass to the left of the exposure glass. The ADF does not use the main exposure glass, unless the user selects book mode and places the originals on the glass (in which case, the ADF mechanism isn’t used - just the cover).
Page 252 21/12/2009 Specifications Table Capacity 50 sheets (80 g/m 2 , 20 lb) Original Standard Position Centre Separation SPECIFICATIONS DF Service manual, page 1 The table capacity is 50 sheets. The original standard position is at the centre. Page 252...
Page 253: Mechanical Component Layout
21/12/2009 Mechanical Component Layout MECHANICAL COMPONENT LAYOUT DF Service manual, page 2 Point out the locations of the major components. The functions of the components can be dealt with in the detailed description sections. Page 253...
Page 254: Electrical Component Layout
21/12/2009 Electrical Component Layout ELECTRICAL COMPONENT LAYOUT DF Service manual, pages 3 and 4 There is one new component, the trailing edge sensor. During one-to-one copying, copy paper is fed to the registration roller in advance, to increase the copy speed. This new sensor monitors the stack of originals in the feeder, and detects when the trailing edge of the last page has been fed in.
Page 255 21/12/2009 Drive Layout DRIVE LAYOUT DF Service manual, page 5 Point out the locations of the major components. The functions of the components can be dealt with in the detailed description sections. Page 255...
Page 256: Original Size Detection
21/12/2009 Original Size Detection One width sensor, and two length sensors Width sensor: Output depends on the guide position Trailing edge sensor: Detects the trailing edge of the final original, to stop the machine from feeding in unwanted copy paper ORIGINAL SIZE DETECTION DF service manual, page 6 The width sensor is a new type.
Page 257 21/12/2009 Pick-up and Separation Pick-up solenoid: Lifts the entrance guide, to lift the originals to the pick-up roller Transport motor: Drives all the rollers Feed clutch: Drives the pick-up roller and feed belt PICK-UP AND SEPARATION DF service manual, page 8 The main points of this mechanism are on the slide.
Page 258 21/12/2009 Original Transport and Feed-out Transport motor: Feeds the original through the scanner Motor speed depends on the reproduction ratio ORIGINAL TRANSPORT AND EXIT DF service manual, page 9 Show the path of paper through the ADF. Point out the DF exposure glass. Go over the points on the slide.
Page 259 21/12/2009 Replacement Separation roller Pick-up roller Feed belt Original set sensor Original width, length, and trailing edge sensors Feed cover and DF open sensors Feed clutch, pick-up solenoid, and transport motor Registration sensor REPLACEMENT DF service manual, pages 11 to 17 Have the class do the procedures on the slide.
Page 260 A: Amount of ink per cartridge For the Silver, this is 600 g Z: Ink consumed per copy The following matrix shows ink consumption (gram) per square meter (m ) for Model HP4-R2. A3 Drum A4 Drum Standard Economy Standard...
Page 261 Example Z: Ink consumption per copy (A3 drum, A4 paper [Type 6200], 6% chart, printing speed:90 cpm, Standard mode) x (0.21 x 0.297) x 0.06 = 0.015g B: Ink consumed per ejected master The amount of ink discarded with the ejected master is a major factor in the ink consumption.

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