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Ricoh Di-C1 Manual

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Machine Codes: D037/D038/D040/D041
Slide 1
HOW TO USE THIS PRESENTATION
This TTP (Technical Training package) will help you train service technicians
on the model Di-C1/C1L.
You can use this guide in three ways:
As a check list to make sure you have covered all the important points
As a set of ordered notes taken from the service manual, operation manual,
and other sources. Sometimes, the ideas from other manuals have been
reworded or reorganized for clarity.
As a source of information that is not included in any of the other manuals.
This may include technical details of the machine's hardware or software, or
background knowledge of technologies used in the machine. This information
can be taught to the trainees if you feel that they will benefit from it, but some
of it may be too technical for routine field use. This information may also help
you answer questions from the class.
Caution: Do NOT give copies of this TTP to anyone other than trainees,
technical training staff, technical support staff, and management personnel.
In particular, do not reveal this information to competitors.
Date of change
Version History
17-11-2008
1.1
MODEL Di-C1 TRAINING
COPIER ENGINE
INTRODUCTION
Description
Changed slides 30, 33, 41, 60, 83, 125, 127,
132, 173, 175, 178, 200, 201, 203, 204, 205,
206, 209, 214, 218, 228, 234, 235, 247, 348,
371, 373
1
Di-C1 Training

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Summary of Contents for Ricoh Di-C1

  • Page 1 HOW TO USE THIS PRESENTATION This TTP (Technical Training package) will help you train service technicians on the model Di-C1/C1L. You can use this guide in three ways: As a check list to make sure you have covered all the important points As a set of ordered notes taken from the service manual, operation manual, and other sources.
  • Page 2 Di-C1 Training PREPARATION CHECK LIST Description Quantity Remarks Field Service Manual 1 per trainee Give copies to the trainees Operation Manual 1 per trainee Give copies to the trainees Training Schedule 1 per trainee Give copies to the trainees Training machines...
  • Page 3 Di-C1 Training Objectives Install the machine and its peripherals in the field. Understand and perform routine maintenance. Understand the PM table. Understand the important SP codes. Troubleshoot and repair this product in the field. Slide 3 ORIENTATION Provide the trainees with information about the training course procedures, facilities, objectives and rules.
  • Page 4 Di-C1 Training Di-C1 TRAINING COPIER ENGINE COURSE OVERVIEW Slide 4 The course is broken up into several modules. This section outlines these modules. The course covers the copier and the optional peripherals. Connectivity is not covered in this course.

  • Page 5: Course Overview

    Di-C1 Training Course Overview - 1 Product Outline Specifications Installation Machine Overview Scanner Laser Exposure PCDU Slide 5 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.
  • Page 6 Di-C1 Training Course Overview - 2 Process Control Toner Supply Transfer Paper Feed Fusing Paper Exit Duplex Slide 6 PROCESS CONTROL This section explains the basic points about how the machine controls the copy process to compensate for changes in operating conditions.
  • Page 7 Di-C1 Training Course Overview - 3 Options ARDF (standard equipment for the H model [Di- C1a/c]) Paper Tray Units (1-tray, 2-tray) Shift Tray One-bin Tray Side Tray Internal finisher Maintenance Troubleshooting Fax Option Slide 7 OPTIONS The options listed above will be described in the indicated order.
  • Page 8 Di-C1 Training Di-C1 TRAINING COPIER ENGINE PRODUCT OUTLINE Slide 8 The model will be introduced. The optional peripherals will be introduced. The product concept, sales points, and targets will be presented.
  • Page 9 Di-C1 Training INTRODUCTION Slide 9 No additional notes...
  • Page 10 Di-C1 Training How many models? Four models: Di-C1a, Di-C1La: 20 cpm Di-C1c, Di-C1Lc: 25 cpm Differences between the models: Di-C1a/c (also known as the ‘H model’): » WVGA display panel » HDD built-in Di-C1La/Lc (also known as the ‘L model’): »...
  • Page 11 Di-C1 Training Appearance – Di-C1a/c Duplex Unit (Built-in) Very compact WVGA Display Internal Finisher Punch Unit Two-tray Paper Tray Unit Slide 11 Here is a view of the machine with some optional peripherals installed. There are other options, as we will see later.
  • Page 12 Di-C1 Training Appearance – Di-C1La/c 4-line LCD Two-tray Paper Tray Unit Slide 12 The duplex unit is not visible in this photo. ADF is standard equipment for Europe and North America; option for Asia and China The display is similar to the K-C3. The K-C3 is a target model for B-to-C...

  • Page 13: Product Positioning

    20 cpm 20/20 cpm 20/20 cpm PG-C2 PG-C2 PG-C1 PG-C1 8/18 cpm 8/18 cpm 6/15 cpm 6/15 cpm FY2005 FY2005 FY2006 FY2006 FY2007 FY2007 FY2008 FY2008 Slide 13 This chart shows the position of the Di-C1 in the product line-up.

  • Page 14: Sales Points

    Di-C1 Training SALES POINTS Slide 14 No additional notes...
  • Page 15 Di-C1 Training Main Sales Points High performance (close to black-and-white models) Short Warm Up time: Less than 30 sec. Short First Copy Output Time: » Black-and-white 6.5 sec » Full colour: 9.5 sec Productivity High speed colour output » Di-C1a/C1La: 20 cpm, Di-C1c/C1Lc: 25 cpm...

  • Page 16: Display Panel

    Di-C1 Training Colour Mode Check Modes Display Panel Icon Job List Remaining Job Time Slide 16 This is for the Di-C1a/c only. The colour mode icon changes when you select Auto Colour Select, Full Colour, or Black and White. Ask the class to try it on the machine, if you have one set up already.
  • Page 17 Di-C1 Training Animated Guidance Slide 17 This is for the Di-C1a/c only. For some functions, such as removing jams and replacing toner, an animated guidance appears on the screen.
  • Page 18 Di-C1 Training Improved Operation Panel Login/Logout, Larger LCD for Authentication Status Lamps Start Key Simplifies Can be seen from a distance the Display Slide 18 This is for the Di-C1a/c only. This type of operation panel has been used for higher-end models for some time now.
  • Page 19 Di-C1 Training Display Normal Display Simplified Display The simplified display appears when you push the Simplified Display button. Slide 19 This is for the Di-C1a/c only.
  • Page 20 Di-C1 Training Easy Jam Removal Simple paper path The cover can be opened without paper falling off the bypass tray. All jams can be removed from the right side of the machine. Slide 20 No additional notes...
  • Page 21 Di-C1 Training EQUIPMENT Slide 21 No additional notes...
  • Page 22 Di-C1 Training Mainframe, with No Options The machine has this equipment built in. Duplex Bypass tray 2x250-sheet trays 500-sheet output tray 8.5-inch W-VGA touch panel (Di-C1a/c only) Printer/Scanner, with USB and Ethernet 768MB Memory (Di-C1a/c), 512 MB Memory (Di- C1La/c)
  • Page 23 Di-C1 Training Paper Handling Options – Di-C1a/c H model H model H model DI-C1 mainframe includes: DI-C1 mainframe includes: • ARDF • ARDF • Auto Duplex • Auto Duplex • Bypass Tray • Bypass Tray 1bin Tray 1bin Tray • 250 sheet x2 •...
  • Page 24 Di-C1 Training Paper Handling Options – Di-C1La/c L model L model L model DI-C1L mainframe includes: • ARDF • Auto Duplex Unit • Bypass Tray • 250 sheets x 2 Side Tray 1bin Tray Note) 500 x 1 paper bank...

  • Page 25: Paper Handling Options

    Di-C1 Training Paper Handling Options All the options are new, except: ARDF: Same as R-C5, AT-C2 Two-tray paper feed unit: Same as Pr-C1, R-C5 Di-C1a/c: The one-bin tray and shift tray cannot be installed in the same machine as the finisher.

  • Page 26: Fax Options

    Di-C1 Training Fax Options Fax Option: New Item There are two fax options. One is for Di-C1a/c, one is for Di-C1La/c Expansion memory (32 MB): Same as R-C5, AL- Handset: Same as AT/AP-C2, R-C5, AL-C1 Fax Stamp Ink: Same as AT/AP-C2, R-C5, AL-C1 There is no optional extra G3 Interface unit.

  • Page 27: Printer/Scanner Options

    Di-C1 Training Printer/Scanner Options Printer/scanner is a standard part of the machine, not an option. USB and Ethernet are built in. PictBridge: Same as G-P3 (enables direct printing from a digital camera) Di-C1a/c only: Wireless LAN (IEEE 802.11g, a/g): Same as AT-C2...

  • Page 28: Security Options

    Di-C1 Training Security Options Di-C1a/c only: Data Overwrite Security Unit: Also used with AL- C1, R-C5 Copy Data Security Unit: Also used with AL-C1, R-C5 HDD Encryption Unit: Also used with AL-C1, R- Slide 28 No additional notes...

  • Page 29: Other Options

    Di-C1 Training Other Options Optional counter interface: Also used with AP/AT-C2 This is a 20-pin interface. It is required when you attach a key counter. Key Counter Bracket: Also used with AP/AT-C2 Di-C1a/c only: File Format Converter: Also used with V-C2, AL-...
  • Page 30 Di-C1 Training Optional USB 2.0/SD card slot This optional unit allows use of the new Scan to USB and Scan to SD features. This allows users to scan documents and save them in electronic format on an SD card or USB memory device.
  • Page 31 Di-C1 Training Optional USB 2.0/SD card slot Up to 2 GB of data can be saved. However, depending on the number of files already stored on the removable memory device, new files might not be saved, even if there appears to be sufficient free space.
  • Page 32 Di-C1 Training TARGETS Slide 32 No additional notes...
  • Page 33 Di-C1 Training Reliability Targets Unit life (2 prints per job): 600K or 5 years Average Copy Volume per month (copy + fax + print): Di-C1a/C1La: 3K Di-C1c/C1Lc: 4K Duty: 40K PM cycle: 60K (drum unit, PCDU toner collection bottle, transfer belt cleaning unit assembly [includes a...
  • Page 34 Di-C1 Training Yield Targets Toner Target Yield (A4/LT, 5% coverage) » Black: 10K outputs/cartridge » Cyan / Magenta / Yellow: 5.5K outputs/cartridge Developer Pre-installed in the machine at the factory, and pre-installed in each development unit spare part. » Europe, USA Di-C1a/c: The heat seal is also removed at the...
  • Page 35 Di-C1 Training Di-C1 TRAINING COPIER ENGINE SPECIFICATIONS Slide 35 No additional notes...

  • Page 36: General Specifications

    Di-C1 Training General Specifications 1 Resolution: Scan: 600 dpi Print: DI-C1L DI-C1 Copy Color 600 dpi 4bit 600 dpi 4bit B&W 600 dpi 1bit 600 dpi 4bit 1200 dpi 1bit Print 600 dpi 2bit/1bit 600 dpi 2bit/1bit Maximum Original Size: A3/11" x 17"...
  • Page 37 For details, refer to “Supported Paper Sizes” in the service manual. Paper Weight From tray 1, DI-C1 supports thick paper (the same paper weight as AT-C2). Paper weight is a key spec for low segment colour MFP users. Why is there such a big difference between the trays for paper weight?
  • Page 38 Di-C1 Training General Specifications 3 Print Paper Capacity (80 g/m , 20 lb): Standard tray: 250 sheets x 2 By-pass tray: 100 sheets Optional paper feed tray: 500 sheets x 2 Output Paper Capacity: Standard exit tray: 500 sheets (A4/LT, 80 g/m...
  • Page 39 Di-C1 Training General Specifications 4 Copy speed Normal (LT/A4 LEF): » C1a/C1La: 20 cpm (colour or black & white) » C1c/C1Lc: 25 cpm (colour or black & white) 1200 dpi, OHP/Thick paper » Both models: 12.5 cpm (colour/black & white) First copy: Colour: 9.5 seconds or less (A4/LT LEF)
  • Page 40 Di-C1 Training General Specifications 5 Memory » Di-C1a/c: 768 MB, Di-C1La/c: 512 MB Hard disk: 60 GB (Di-C1a/c only) Optional memory: 512 MB (Di-C1a/c only) » Up to 2 units can be installed (up to 1 GB) Slide 40 The fax option has an additional memory module. The purpose is explained...
  • Page 41 Di-C1 Training Thick Paper Productivity Paper BK CPM FC CPM BK CPM FC CPM Mode Thickness (g/m Thin Paper 52-59.9 Plain Paper 1 Plain Paper 2 Middle Thick -105 Thick Paper 1 -169 12.5 12.5 12.5 12.5 Thick Paper 2 -210 12.5...

  • Page 42: Copier Specifications

    Di-C1 Training Copier Specifications Model DI-C1L Model DI-C1 Mixed Sizes Originals Mode Advanced Reduce/Enlarge Copying Advanced Copier Functions (Booklet/Magazine, Covers, Stamps, etc.) O (Only B&W) Electrical Sort O (With Finisher) Staple/Punch Slide 42 X: Not available O: Available ACS: This refers to the machine’s ability to detect whether the original is b/w or colour (the L model cannot do this;...
  • Page 43 Di-C1 Training Scanner/Fax Specifications Model DI-C1L Model DI-C1 Scan to functions Document Server (Local Storage) LAN FA X (No print function) Internet FA X IP FA X FA X forwarding Solution Slide 43 X: Not available O: Available...

  • Page 44: Printer Specifications

    Di-C1 Training Printer Specifications (1) Model DI-C1L Model DI-C1 Built in standard Built in standard Printing Module Controller CPU RM5231A-400MHz RM7035C-533MHz Print Speed C1La: FC 20ppm/ BW 20ppm C1a: FC 20ppm/ BW 20ppm (A4/LT LEF) C1Lc: FC 25ppm/ BW 25ppm...
  • Page 45 Di-C1 Training Printer Specifications (2) Model DI-C1L Model DI-C1 Network Prot ocol TCP/IP(IPv4, IP v6), IP X/SP X TCP/IP(IPv4, IP v6) , IP X/SP X, AppleTalk Print Resolution 600 x 600 dpi / 1bit 600 x 600 dpi / 1bit...

  • Page 46: Product Comparison

    Di-C1 Training Product Comparison Di-C1 Di-C1L AT-C2 K-C3cd Dimensions (W x D x H, mm) 587 x 655 x 725 670 x 671 x 760 587 x 568 x 558 Weight (kg) Scan Resolution (dpi) Max. Copy/Print Resolution (dpi) 1200 1200 Max.
  • Page 47 Di-C1 Training Product Comparison Di-C1 Di-C1L AT-C2a/b K-C3cd Copy Speed (A4/LT LEF, cpm) C1a: 20/20 C1La: BW: 28/33 BW: 20 20/20 FC: 28/33 C1c: 25/25 C1Lc: 25/25 Copy Speed (seconds) BW: 6.5 BW: 5 BW: 6.5 FC: 9.5 FC: 8...
  • Page 48 Di-C1 Training Di-C1 TRAINING COPIER ENGINE INSTALLATION Slide 48 Install at least one machine with all options as a complete system. Follow all notes and cautions in the procedures.
  • Page 49 Di-C1 Training COPIER Important Points Slide 49 No additional notes...
  • Page 50 Di-C1 Training Shipping Retainer for Scanner Remove this stay Remove the scanner unit stay and keep it in the cutout in the inner tray. Europe models: The scanner unit stay cannot be inserted in the cutout on the inner tray. You must bring it back to your depot.
  • Page 51 The development units can be severely damaged if you do not remove the tape. Slide 51 In the following models, the tape is removed at the factory. Europe: All models USA: Di-C1 a/c...
  • Page 52 Di-C1 Training Check the Toner Hopper Shutter The toner hopper shutter must be fully closed (as shown on the left). If the toner hopper shutter is not fully closed and the inlet of the toner hopper unit is visible (as shown on the right), the toner bottle cannot be installed properly.
  • Page 53 Di-C1 Training Toner Bottles Shake each bottle 5 or 6 times before you install it. When the toner bottle is installed, the bottle must be turned to the right (clockwise). This opens the bottle, and toner can leave the bottle.

  • Page 54: Initializing The Developer

    Di-C1 Training Initializing the Developer This is done automatically after you turn the power on for the first time. When it is finished, the LED on the Start key goes green. If the initialization does not finish correctly, you can use SP 3014 001 to see what the problem is.
  • Page 55 Di-C1 Training SP Settings (1) Counting method: SP5-045-001 Specifies whether the counting method used in meter charge mode is based on developments or prints. » The default setting is ‘developments’. A3/11" x 17" double counting: SP5-104-001 The default setting is ‘single counting’. When you have to change this setting, contact your supervisor.
  • Page 56 Di-C1 Training SP Settings (2) Service Tel. No. Setting: SP5-812-001 through 004 001: Service station telephone number 002: Service station fax number. This number is printed on the counter list when meter charge mode is selected. This lets the user fax the counter data to the service station.
  • Page 57 Di-C1 Training Fax Settings (D037-17) The D037-17 model has a built-in fax unit. Fax settings must be made during the copier’s installation procedure. See the service manual for the fax option. Slide 57 D037-17 is the USA model of the Di-C1La (20 cpm model)
  • Page 58 Di-C1 Training PAPER TRAY UNITS Important Points Slide 58 No additional notes...

  • Page 59: Important Notes

    Di-C1 Training Important Notes The one-tray paper feed unit must be installed with the caster table. Slide 59 ALSO You must lift the copier and put it on top of the paper tray unit. Always lift with two persons. The copier is too heavy for one person.
  • Page 60 Di-C1 Training Caster Table If the one-tray feed unit is installed directly on the caster table Use this in either of these cases If the copier is installed on the caster table Use the correct screw hole when installing the caster table.
  • Page 61 Di-C1 Training SHIFT TRAY, ONE-BIN TRAY Important Points Slide 61 No additional notes...
  • Page 62 Di-C1 Training Install in This Order Install the shift tray unit first. Installing the shift tray unit after the 1-bin tray unit may be difficult. Slide 62 No additional notes...
  • Page 63 Di-C1 Training FINISHER AND PUNCH UNIT Important Points Slide 63 No additional notes...
  • Page 64 Di-C1 Training Service Manual Procedures Internal Finisher: This procedure explains how to install the internal finisher, without installing the punch unit at the same time. Punch Unit: There are procedures for A) Installing the punch unit if the internal finisher...
  • Page 65 Di-C1 Training Inserting the Joint Pins Insert the two joint pins before attaching the front side of the inverter unit to the paper exit unit of the mainframe. Otherwise, paper jams may occur between the paper exit unit and inverter unit.
  • Page 66 Di-C1 Training USB/SD CARD SLOT Important Points Di-C1a/c Only Slide 66 No additional notes...
  • Page 67 Di-C1 Training Connect the Right-hand Slot If you connect the USB/SD option to the left-hand slot, the cable will prevent the user from connecting a camera to the other slot. Connect it here Slide 67 No additional notes...
  • Page 68 Di-C1 Training USB/SD Slot After you install this unit, it must be enabled with an SP mode (see the installation procedure for details). Test the operation of this device after installation. Try to scan a document and store it to the SD card or USB memory device.

  • Page 69: Controller Options

    Di-C1 Training CONTROLLER OPTIONS Important Points Slide 69 No additional notes...
  • Page 70 Di-C1 Training Board and Card Slots (1) Fax Option Fax Option: Install the fax option here. I/F Board slot (Di-C1a/c only): Install one of the following IEEE1284 IEEE802.11a/g, g Bluetooth File Format Converter Gigabit Ethernet I/F Board Slot Slide 70...
  • Page 71 Di-C1 Training Board and Card Slots (2) SD Card Slots (Di-C1a/c) Slot 1: Install one of the following » PostScript 3; do not copy to another SD Card. » Data Overwrite Security Unit » PictBridge Slot 2: VM Kit, Service...
  • Page 72 Di-C1 Training Board and Card Slots (3) SD Card Slots (Di-C1La/c) Slot 1: Printer Enhanced Option (PCL option) Slot 2: Service only (for example, updating the firmware). SD Slot 1 SD Slot 2 Slide 72 No additional notes...
  • Page 73 Di-C1 Training Board and Card Slots (4) USB Slots Di-C1a/c: Two slots Di-C1La/c: One slot The following can be connected to a USB slot USB Slots USB2.0/SD option (Di- C1a/c only) » Connects to the right- hand slot during installation.

  • Page 74: Sd Card Slots

    Di-C1 Training SD Card Slots Slot 1 (Di-C1a/c) One of these can be installed. » PostScript 3, Data Overwrite Security Unit, PictBridge To install more than one, you must merge the software onto one card. » Procedure: We will study later in this section Do not copy the PostScript card onto another card.
  • Page 75 Di-C1 Training SD Card Slots Slot 2 It is used for installing new firmware. Di-C1a/c: It is also used during the installation procedure for the browser unit, VM card, or HDD encryption unit. » The machine copies firmware from the SD card to the hard disk during the procedure.

  • Page 76: Moving Applications

    Di-C1 Training Moving Applications If you want to use more than one of the ‘slot 1 applications’, you must move the application from the original card to another SD card. See the service manual for the detailed procedure. Basic points: Put the source card in slot 2, and copy it to the card in slot 1.
  • Page 77 Di-C1 Training Storing the Original SD Cards after Merging Cover Lever Store the cards here After you move an application, the original SD card is de- activated. It can be re-activated with the ‘Undo Exec’ procedure in the service manual.
  • Page 78 Di-C1 Training IEEE802.11a/g, g Interface (1) Make sure to install the antennas correctly, as described in the manual. "ANT1" is a transmission/reception antenna and "ANT2" is a reception antenna. Do not attach them at the wrong places. Slide 78 No additional notes...
  • Page 79 Di-C1 Training IEEE802.11a/g, g Interface (2) Refer to the above picture when installing the USB2.0/SD slot. Slide 79 No additional notes...

  • Page 80: Transporting The Machine

    Di-C1 Training TRANSPORTING THE MACHINE Slide 80 No additional notes...
  • Page 81 Di-C1 Training Moving the Machine a Short Distance Remove all trays from the optional feed unit. Slide 81 Service manual, Installation, Copier Installation, Moving the Machine...
  • Page 82 Di-C1 Training Moving the Machine a Long Distance (1) Move the scanner carriage from home position. Use SP 4806 001. This prevents dust from getting into the scanner. Remove the paper from the paper trays, and secure the bottom plates with tape.
  • Page 83 Di-C1 Training After Moving the Machine a Long Distance Do the "Auto Colour Registration" as follows. This optimizes colour registration. First, do "Forced Line Position Adj. Mode c" (SP2- 111-3). Then, do "Forced Line Position Adj. Mode a" (SP2-111-1). To check if SP 2-111-1 was successful, watch the screen during the process.
  • Page 84 Di-C1 Training INSTALL THE MACHINE AND OPTIONS Slide 84 No additional notes...
  • Page 85 Di-C1 Training Install the Following Install the Following Copier Paper Handling Options » Paper feed units » Caster table (for the one-tray paper feed unit) » ARDF and/or platen cover » Side tray » One-bin tray » Shift tray » Internal finisher and punch unit »...
  • Page 86 Di-C1 Training Other Options Mechanical counter (NA only) After you install the mechanical counter and enable it with SP 5987, then SC611 occurs if you try to remove it. This is to prevent falsification of the counter setting. Key counter interface...

  • Page 87: Updating The Firmware

    Di-C1 Training UPDATING THE FIRMWARE Slide 87 Install the latest firmware in the machine.

  • Page 88: Downloading New Software

    Di-C1 Training Downloading New Software All firmware is on SD cards. The firmware SD card plugs into SD card slot 2. Update the firmware. Verify the update was successful Update the operation panel firmware. Controller firmware and operation panel firmware cannot be updated at the same time.
  • Page 89 Di-C1 Training Backing Up NVRAM Data Copy the data to an SD card. The SD card plugs into slot 2. Use SP5824 001 SP 5825 001 copies the data from the SD card to the machine. The data is copied to a folder in the SD card, into a file with the filename taken from the machine’s serial number...
  • Page 90 Di-C1 Training Backing Up the Address Book Data Copy the data to an SD card. The SD card plugs into slot 2. Use SP5846 051 SP 5846 052 copies the data from the SD card to the machine. Slide 90...
  • Page 91 Di-C1 Training Di-C1 TRAINING COPIER ENGINE MACHINE OVERVIEW Slide 91 No additional notes...

  • Page 92: Mechanical Components

    The paper feeds up to the fusing unit, and out of the machine. In the AT-C1 series, the order of drums from left to right is YCMK. In the Di-C1 it is YMCK. Why? K is always at the right end, because it must always contact the transfer belt, which moves away from the colour drums for black-and-white pages.
  • Page 93 Di-C1 Training Mechanical Component Overview (1) Laser optics unit There are four lasers, and four sets of optics. One for each toner colour (KYCM). Each polygon mirror reflects light from two laser diodes. PCDU (Photoconductor and Development Unit) There are four units, one for each toner colour.
  • Page 94 Di-C1 Training Mechanical Component Overview (2) Image transfer unit Bias rollers opposite the OPC drums transfer toner from the drums to the transfer belt. Four toner images are super-imposed onto the belt. Paper transfer roller unit The ITB drive roller pushes the toner from the transfer belt to the paper (the transfer roller is an idle roller).

  • Page 95: Paper Path

    Di-C1 Training Standard Output Paper Path Tray Inverter Duplex Unit Bypass Tray Paper Feed Trays Slide 95 This shows the path of paper through the machine, with no optional paper handling units installed. Demonstrate the following feed paths on the diagram.
  • Page 96 Di-C1 Training Standard Output Paper Path Path Optional Proof Side Tray Tray Optional Finisher Optional Paper Feed Trays Slide 96 This shows the path of paper through the machine, with the optional finisher, side tray, and paper feed unit (2-trays) installed.

  • Page 97: Drive Layout

    Di-C1 Training Drive Layout Drum/Development Drive Motor-K Drum Drive Motor-CMY Development Development Clutch-K Drive Motor-CMY Slide 97 This shows the main motors in the machine. Notes: The PCDU for K has one motor to drive the drum and development unit.

  • Page 98: Ventilation And Cooling

    Di-C1 Training Ventilation and Cooling Slide 98 No additional notes...

  • Page 99: Board Structure

    Di-C1 Training Board Structure Slide 99 This shows a schematic of the electrical layout of the machine. The orange line through the centre from the SBU to the LDB is the flow of image data through the machine. The CCD (Charged Coupled Device) generates analog RGB signals.

  • Page 100: Board Layout

    Di-C1 Training i-Controller Board i-Controller Board Board Layout (1) (Di-C1La/c) (Di-C1a/c) HDD (D038/D041) Slide 100 Here, the controller box is closed.
  • Page 101 Di-C1 Training HVPS: TTS Board Layout (2) HVPS: CB Slide 101 Here, the controller box is open. HVPS: CB – Drum charge and development bias HVPS: TTS – Image transfer...

  • Page 102: Main Boards

    Di-C1 Training Main Boards The BCU controls the engine. The controller (called iCTL) handles the network and printer interfaces, and the operation panel. It also contains the image processing circuits. The SBU contains a CCD. The DRB contains driver circuits for motors.

  • Page 103: Printing Process

    Di-C1 Training Bias Roller ITB Drive Printing Process Roller Drum Image Transfer Belt (ITB) Paper Four PCDUs, one laser unit (four laser beams). Transfer Each PCDU contains an OPC drum and a development unit. Roller Bias rollers above each OPC drum pull the four developed toner images to the ITB, to deposit a four-colour image on the ITB.
  • Page 104 Di-C1 Training Process Speeds There are two process speeds, as follows: Thin, Plain, or Middle Thick Paper: 120 mm/s » Print speed (ppm): C1a: 20, C1c: 25 1200 dpi, OHP/Thick Paper: 60 mm/s » Print speed (ppm): 12.5 Slide 104 The process speed is the feed speed from registration roller to the fusing unit.
  • Page 105 Di-C1 Training New Unit Detection Mechanisms PCDU, Development Unit The development unit (as part of the PCDU, or as a separate development unit) contains an ID chip. The ID chip contains information that tells the machine that the unit is new.

  • Page 106: Replacement Of Electrical Components

    Di-C1 Training Replacement of Electrical Components Take care when replacing these parts. Follow the instructions in the manual. iCTL board Hard disk NVRAM Drum Motor: CMY Do not remove the PCDUs when you replace this motor. Gear unit Do SP1902-001 (Drum Phase Adjustment) after you replace the gear unit.
  • Page 107 Di-C1 Training Replacing the iCTL Remove the NVRAM from the old iCTL and install it on the new one. Make sure that you install the correct board. There are 4 models. The iCTL board is different for each one. If you install the wrong board, the machine will not work.
  • Page 108 Di-C1 Training Replacing the BCU Remove the NVRAM from the old BCU and install it on the new one. Turn the machine on. SC995-01 appears. This means that the serial number is not stored. Store the serial number with SP 5811-004.

  • Page 109: Hard Disk Removal

    Di-C1 Training Hard Disk Removal Remove the hard disk. After installing the new disk: Copy the stamp data to the disks from the firmware: SP5853. Then switch the machine power off/on. It is not necessary to format the hard disk.
  • Page 110 Di-C1 Training Hard Disk Removal (1) Explain to the customer that the following information stored on the HDD is lost when the HDD is replaced: Document server documents Custom-made stamps Document server address book The address book and document server documents (if needed) must be input again.
  • Page 111 Di-C1 Training Hard Disk Removal (2) If the customer uses the DOS unit option, this option must be set up again after a new hard disk is installed. If the HDD encryption unit is installed, the user must copy the encryption key from the controller to the new hard disk.
  • Page 112 Di-C1 Training Hard Disk Removal (3) Before you install a new unit: Do SP 5846 051 to copy the address book from the hard disk to an SD card (put the SD card in slot 1). After you install a new unit: Do SP5853 001 to download the fixed stamps from the ROM to the HDD.

  • Page 113: Disposal Of Hdd Units

    Di-C1 Training Disposal of HDD Units Never remove an HDD unit from the work site without the consent of the client. If the customer has any concerns about the security of any information on the HDD, the HDD must remain with the customer for disposal or safe keeping.
  • Page 114 Di-C1 Training Di-C1 TRAINING COPIER ENGINE SCANNER Slide 114 In this section, the mechanical components of the scanner will be described. The optional ADF is described in a separate section.

  • Page 115: Optical Path

    Di-C1 Training Optical Path ADF Exposure Glass Main Exposure Glass Exposure Lamp One exposure lamp 3-line colour CCD Anti-condensation heater is optional No adjustments required in the field for the CCD and lens block Slide 115 In platen mode, the original is put on the main exposure glass, and the scanner moves down the original during scanning.

  • Page 116: Scanner Drive

    Di-C1 Training Scanner Scanner Drive HP Sensor Scanner Motor Motor and wire drive mechanism Slide 116 The same motor drives the first and second scanners. The first scanner contains the exposure lamp, reflectors, the 1st mirror, and the lamp regulator. The second scanner contains the 2nd and 3rd mirrors.
  • Page 117 Di-C1 Training Original Size Detection – Platen Mode Platen Cover Sensor Length Sensors Reflective photosensors detect the length. The CCD detects the width. Slide 117 When the ADF is opened, the scanner carriage moves 30 mm from the home position.

  • Page 118: Replacement And Adjustment

    Di-C1 Training Replacement and Adjustment Service Manual, Replacement and Adjustment, Image Adjustments Do these adjustments after you replace one of these parts: Original Length Sensors, Lens Block, Scanner Motor, Scanner Wires Main Exposure Glass Position the marker at the front-left corner.
  • Page 119 Di-C1 Training Di-C1 TRAINING COPIER ENGINE LASER EXPOSURE Slide 119 The optics and electronics in the laser unit will be described in this section.
  • Page 120 Di-C1 Training Overview One laser beam for each colour. Two polygon mirrors attached to the same motor. Polygon Mirrors The upper mirror reflects yellow and black. The lower mirror reflects magenta and cyan. Slide 120 Black also has one beam only.
  • Page 121 Di-C1 Training Synch: Optic Components K (Start) LD Board: LD Board: Y, M K, C Synch: Y (Start) Four laser diodes, one for each colour. Two laser synchronization detector boards: Each board is used by 1 colour Each colour is detected at the start of the main scan...

  • Page 122: Ld Safety Switches

    Di-C1 Training LD Safety Switches Slide 122 Make sure that you understand how the cover switches cut the laser power. The switches used are the front and duplex unit.
  • Page 123 Di-C1 Training Automatic Line Position Adjustment Front C enter R ear LP 1 During automatic line position adjustment, the line patterns above are created on the transfer belt. Slide 123 The spaces between the lines are measured by the front, center, and rear ID sensors.
  • Page 124 Di-C1 Training Automatic Line Position Adjustment The spaces between the lines are measured by the front, center, and rear ID sensors. The controller takes the average of the spaces. Then it adjusts the following positions and magnification. Sub scan line position for CMY...
  • Page 125 Di-C1 Training ID Sensors Three ID sensors, on the ID sensor board: All three are used for line position adjustment The one in the center is also used for process control Do not wipe the sensors with a dry cloth. Use a cloth moistened with alcohol.
  • Page 126 Di-C1 Training More about the Adjustments Sub scan line position for CMY The adjustment of the sub-scan line position for CMY is based on the line position for K (colour registration). » The machine measures the gaps between the lines of each colour in the pattern on the transfer belt.

  • Page 127: Adjustment Conditions

    Di-C1 Training Adjustment Conditions (1) Initial: Immediately after the power is turned on, if one of the following conditions are met. » Time after drum motor stops (SP3522-002) » Temperature change since the previous line position adjustment (SP2193-008/011) » Number of prints (SP2193-016) since the previous line position...
  • Page 128 Di-C1 Training Adjustment Conditions (2) During a job: The job is interrupted and the adjustment is done once, depending on: » Time since the previous line position adjustment » Temperature change since the previous line position adjustment » Number of prints since the previous line position...
  • Page 129 Di-C1 Training Adjustment Conditions (3) At the end of a job: The adjustment is done once, depending on: » Time since the previous line position adjustment » Temperature change since the previous line position adjustment » Number of prints since the previous line position...
  • Page 130 Di-C1 Training Adjustment Conditions (4) When the front door is opened and closed: The adjustment is done once (or twice), depending on: » Time since the previous line position adjustment » Temperature change since the previous line position adjustment The machine checks the above conditions after the front door is opened/closed.
  • Page 131 Di-C1 Training Adjustment Conditions (5) In standby mode (but not in energy saver mode): The adjustment is done once, depending on: » Time since the previous line position adjustment » Temperature change since the previous line position adjustment » Number of prints since the previous line position...
  • Page 132 Di-C1 Training Adjustment Conditions (6) Forced line position adjustment: You can do this at any time with SP 2111. » It must be done after installing a new laser optics unit or polygon mirror, or after moving the machine. There are three adjustments.
  • Page 133 Di-C1 Training MUSIC - Main Scan Skew Correction Mirror (M) Mirror (C) Mirror (Y) Mirror Mirror Mirror Positioning Positioning Positioning Motor (Y) Motor (M) Motor (C) The 2nd mirrors for C, M, and Y each have a motor. The angle of each 2nd mirror can be adjusted by these motors.
  • Page 134 Di-C1 Training Laser Unit Cooling One fan blows cool air into the laser unit. Slide 134 The other two fans in this diagram are for the development unit.

  • Page 135: Service Remarks

    Di-C1 Training Service Remarks SWITCH THE POWER OFF AND UNPLUG THE POWER CORD BEFORE STARTING WORK ON THE LASER UNIT Do not loosen the LD board securing screws. Do not adjust any of the VRs. Do not open the optical housing unit except when absolutely necessary for servicing.
  • Page 136 Di-C1 Training Laser Optics Housing Unit Replacement (1) First, prepare the new laser optics housing unit. Then, before you switch the machine off, you must make some SP adjustments. These adjustments move the 2nd mirror positioning motors back to home position.
  • Page 137 Di-C1 Training Laser Optics Housing Unit Replacement (2) The sheet that is packed with the new laser optics housing unit clearly shows which numbers to store in the SP modes. If that is not enough, look at the replacement procedure in the service manual for a full explanation.

  • Page 138: Polygon Mirror Motor

    Di-C1 Training Polygon Mirror Motor After you install a new unit, you must do the forced line position adjustment (SP 2111 003, then 2111 001). Slide 138 No additional notes...

  • Page 139: Image Adjustments

    Di-C1 Training Image Adjustments Service Manual, Replacement and Adjustment, Image Adjustments These image adjustments must be done after replacing the laser optics housing unit or the polygon mirror motor. Slide 139 No additional notes...
  • Page 140 Di-C1 Training Di-C1 TRAINING COPIER ENGINE PCDU Slide 140 No additional notes...
  • Page 141 Di-C1 Training Overview Development Drum Unit Cleaning Brush Cleaning Blade Charge Roller PCDU = Development unit + Drum unit Drum diameter: 30 mm Development roller diameter: 18 mm Slide 141 The PCDU is divided into two parts, as shown by the red boxes on this slide.
  • Page 142 Di-C1 Training Overview Drum Cleaning Brush Cleaning Blade Development Charge Roller Roller One PCDU for each colour. The drum units are identical and can be interchanged. But the development units cannot (they already contain developer). Four colours are developed at the same time.
  • Page 143 Di-C1 Training Drum Drive - K Drum Gear Position Sensor - K Drum/Development Drive Motor - K The same motor drives the development unit for K. The drum gear position sensor detects when the motor is not working. It also makes sure that the drum gear is at the correct angle when printing starts.
  • Page 144 Di-C1 Training Drum Drive - CMY Drum Drive Motor - CMY Drum Gear Position Sensor - CMY This motor drives three drums. It does not drive the development units. The drum gear position sensor detects when the motor is not working.

  • Page 145: Charge Roller

    Di-C1 Training Charge Roller Drum The roller does not contact the drum (there is a very small gap between roller and drum). The cleaning roller always contacts the charge roller. Charge Roller Charge Cleaning Roller Roller Slide 145 No additional notes...
  • Page 146 Di-C1 Training Charge Roller Voltage The charge roller gives the drum surface a negative charge. An ac voltage is also applied to the charge roller, at a constant current. The ac voltage helps to ensure that the charge given to the drum is as uniform as possible.
  • Page 147 Di-C1 Training Quenching The laser exposes all areas of the drum at the end of each job. This removes any charges remaining on the drum. Slide 147 No additional notes...

  • Page 148: Drum Cleaning

    Di-C1 Training Drum Cleaning Cleaning Brush The cleaning blade removes remaining toner Lubricant from the drum. This toner falls onto a collection coil, and is discarded. The cleaning brush applies lubricant to the drum. The cleaning blade spreads this lubricant.
  • Page 149 In the AT-C1, toner from all four drums is collected in one coil before it goes to the bottle. In the G-P3/Di-C1, there are four openings in the bottle, and toner goes directly from the drum into the bottle, and is...
  • Page 150 Di-C1 Training Toner Bottle Detection/Full Detection Near-full Sensor Bottle Set Sensor When the waste toner sensor detects the actuator, the ‘near-full’ condition occurs. The machine can make about 2000 more copies (2 P/J, 20% colour ratio, 5% coverage). Then the ‘full’ condition occurs and the machine stops.
  • Page 151 Di-C1 Training Mixing Development Augers Development Dual component developer Roller TD sensor in each development unit The TD sensor contains the ID chip that contains information about the PCDU. TD Sensor/ ID Chip Slide 151 No additional notes...
  • Page 152 Di-C1 Training Development Drive - K Development Clutch Drum/Development Drive Motor - K The drum/development drive motor controls the K development unit. This motor also controls the K drum, so a clutch is necessary. Slide 152 No additional notes...
  • Page 153 Di-C1 Training Development Drive - CMY Development Drive Motor - CMY This motor drives the C, M, and Y development units. Slide 153 This motor does not control the drums, so no clutch is necessary.

  • Page 154: Developer Agitation

    Di-C1 Training Developer Agitation Development Roller Mixing Augers Two augers circulate the toner in the development unit during development, during toner supply, and during process control self checks. Slide 154 This diagram shows how the augers move the toner around inside the...
  • Page 155 Di-C1 Training Development Unit Storage If the development unit was stored at more than 40 °C, the developer can become solid. If this occurs, you will get a developer initialization error at installation. At this time, you must do the following...

  • Page 156: Refresh Mode

    Di-C1 Training Refresh Mode While making prints with low coverage, the developer is agitated with less toner consumption and the toner carrier attraction tends to increase. This may cause low image density or poor transfer (white dots). To prevent this, the coagulated toner or overcharged toner must be consumed.

  • Page 157: New Unit Detection

    Di-C1 Training New Unit Detection (1) The TD sensor assembly contains the ID chip. This chip tells the machine if the PCDU or development unit is new or not. When the machine detects a new PCDU or development unit, the machine automatically...
  • Page 158 Di-C1 Training New Unit Detection (2) If you install a new drum unit only, the machine does not detect it automatically. Then, you must reset the PM counter for the drum unit. To do this, set SP 3902 009 (K), 010 (C), 011 (M), or 012 (Y) to 1 before you start to work on the machine.
  • Page 159 Di-C1 Training ID Chip The ID chip is part of the TD sensor assembly. The ID chip contains counters and other data about the PCDU, drum unit, and development unit. Slide 159 No additional notes...

  • Page 160: Replacement And Adjustment

    Di-C1 Training Replacement and Adjustment Development Unit Do the ACC procedure after the developer initialization is finished. » User tools > Maintenance > ACC > Start Slide 160 Under normal conditions, the life of the developer is the same as the machine, so it is not necessary to replace.
  • Page 161 Di-C1 Training Replacement and Adjustment PCDU Toner Collection Bottle If you replace the bottle after the machine detects that it is full or near-full, the machine automatically resets the PM counter for the bottle after replacement. But, if you replace a bottle that is not full or near- full, then you must reset the PM counter for this unit.
  • Page 162 Di-C1 Training Replacement and Adjustment When installing a new PCDU Remove the cover on the Cover toner inlet and pull out the tape from the new development unit before installing a new PCDU in the machine. Tape Slide 162 No additional notes...
  • Page 163 Di-C1 Training Di-C1 TRAINING COPIER ENGINE PROCESS CONTROL Slide 163 Process control will be described briefly in this section.
  • Page 164 Di-C1 Training Overview Slide 164 No additional notes...
  • Page 165 Di-C1 Training What is Done? This machine has two forms of process control. Potential control Toner supply control Process control uses these components: The central ID sensor » There are three ID sensors. Only one is used for process control...
  • Page 166 Di-C1 Training TD Sensor Toner Each development Bottle unit has a TD sensor. TD Sensor/ID Chip Development Toner End Unit Sensor Slide 166 No additional notes...

  • Page 167: Potential Control

    Di-C1 Training Potential Control Slide 167 No additional notes...
  • Page 168 Di-C1 Training Overview The machine determines the best possible V , and V , based on current machine conditions. : Drum potential without exposure – to adjust this, the machine adjusts the charge roller voltage. : Development bias : Drum potential at the strongest exposure – to...
  • Page 169 Di-C1 Training When is it Done? (1) Initial: Immediately after the power is turned on, or when the machine recovers from the energy saver mode. Done if one of these conditions occurs: » Temperature has changed by more than a certain amount after the drum motor stopped.
  • Page 170 Di-C1 Training When is it Done? (2) At the end of a job: Done if 250 b/w or 100 full colour prints were made since the previous adjustment (SP 3515 001/002). During a job: Done if 500 b/w or 200 full colour prints were made since the previous adjustment (SP 3515 003/004).
  • Page 171 Di-C1 Training When is it Done? (3) After replacing the development unit: Process control occurs automatically After replacing the following units, process control must be done manually with SP 3-902 (PM counters are reset then process control is done) ITB unit...
  • Page 172 Di-C1 Training Toner Density Adjustment Mode Overview Process control adjusts the toner density so that the density of each colour in the image is correct. But, sometimes, process control adjusts the toner density too slowly, and the first few copies after process control have incorrect toner densities.
  • Page 173 Di-C1 Training Toner Density Adjustment Mode What is Done? The machine makes sensor patterns and checks the current development gamma. Development gamma too low: If the following condition occurs, the machine increases the toner density. To do this, it supplies toner to the development unit.
  • Page 174 Di-C1 Training Toner Density Adjustment Mode When is it Done? After power-on (toner supply mode only, no consumption) Before ACC In this way, the customer can execute the toner density adjustment mode, if they think that colour balance is not good. It becomes part of the ACC process.
  • Page 175 Why is it quicker? The sensor pattern is made while the last page of the job is still feeding out of the machine. In the AT-C1, the machine waits until the paper is completely fed out before the patterns are made. Also, for black and white, the Di-C1 only makes the black sensor pattern.

  • Page 176: Toner Supply Control

    Di-C1 Training Toner Supply Control Slide 176 No additional notes...
  • Page 177 Di-C1 Training Overview Uses these components: TD sensor: Detects how much toner there is in the developer ID sensor: Measures the density of standard sensor patterns during process control. Pixel counter: Counts pixels to determine how much toner for each colour is used on the page The result of toner supply control determines how long the toner supply motor turns on for.
  • Page 178 Di-C1 Training Toner Supply Control Modes This machine uses 5 toner supply modes. The mode used depends on SP3-044-001 to –004. These are the five modes: PID control mode PID control mode with fixed VT Fixed supply mode MBD control mode: This is the default mode.
  • Page 179 Di-C1 Training Toner Supply Control PID control mode Uses the TD sensor, ID sensor, and pixel count. VTREF is adjusted by process control. PID control mode with fixed VTREF Change to this mode if the ID sensor breaks. This mode uses only the TD sensor.
  • Page 180 Di-C1 Training Other SP Modes Slide 180 A lot of SPs were already discussed. Here are other SPs related to process control.
  • Page 181 Di-C1 Training Potential Control – Others Enable/disable 3041 001: Potential control, enable/disable 3041 002: LD power control, enable/disable 3041 004: What type of process control is done before ACC (default: TD adjustment only) Forced process control 3011 001: Normal process control, manual execution...
  • Page 182 Di-C1 Training What Values are used if Potential Control is Disabled? If potential control is disabled (SP3-041-001 is set to 0), V and V are fixed by SP mode settings. SP2-005 for V , SP2-229 for V If LD power control is disabled (SP3-041-002 is set to 0), the LD power is fixed by an SP mode setting.
  • Page 183 Di-C1 Training Di-C1 TRAINING COPIER ENGINE TONER SUPPLY Slide 183 In this section, the mechanical components of the toner supply system will be described. Toner supply control was explained in the Process Control section of the course.
  • Page 184 Di-C1 Training Overview Toner Bottle Development Unit Toner End Sensor TD Sensor To supply toner, the toner bottle is rotated. The toner goes down a tube, and goes into the sub hopper. The toner end sensor is attached to the sub hopper.
  • Page 185 Di-C1 Training Toner Bottle Rotation Toner Bottle Motor Each bottle is controlled by a separate motor. There are no clutches Toner Bottle Toner End Sensor Slide 185 No additional notes...

  • Page 186: Toner Bottle

    Di-C1 Training Toner Bottle Toner Bottle Development Unit Toner End Sensor TD Sensor When the toner bottle is installed, the bottle must be turned to the right (clockwise). This opens the bottle, and toner can leave the bottle. The spiral grooves in the bottle help to feed toner out of the rotating bottle.

  • Page 187: Toner Hopper Unit

    Di-C1 Training Toner Hopper Unit Toner Hopper The toner hopper contains a small amount of carrier. This prevents large amounts of toner from entering the development unit during a long job with high image coverage. If a lot of toner is allowed to enter, toner scattering may occur.
  • Page 188 Di-C1 Training Radio Frequency ID Chip RFID Chip Antenna Board Each toner bottle has a chip. This chip contains data on the amount of toner consumed from the bottle, and is used for toner bottle detection (the machine uses it to detect if the bottle installed or not).

  • Page 189: Toner Near-End Detection

    Di-C1 Training Toner Near-end Detection To detect toner near-end, the machine uses the following data: Toner supply motor rotation counter Pixel counter Toner end sensor If one (or both) of the counters detect that the remaining toner amount is less than a set value (see below), the machine enters the near-end condition.
  • Page 190 Di-C1 Training Toner Near-end Detection Method 3045 002 0: Pixel counter, motor rotation counter, and toner end sensor 1: Toner end sensor only Slide 190 If set to 1, there is no toner in the toner cartridge at the near end condition.

  • Page 191: Toner End Detection

    Di-C1 Training Toner End Detection To detect toner end, the machine uses the TD sensor (there is one below each toner bottle). Toner end is detected if both of these conditions occur: ≥ 0.5 » V – V TREF ) ≥ 10 »...
  • Page 192 Di-C1 Training What Happens if Toner End is Detected? If toner end is detected for black, the toner bottle must be replaced or the machine cannot print. If toner end is detected for C, M, or Y, the machine can print in black and white only. Colour print jobs cannot be started.

  • Page 193: Toner End Recovery

    Di-C1 Training Toner End Recovery The machine assumes that the toner cartridge was replaced if either of the following occurs when the near-end or end status exists: The front door is opened and closed. The main switch is turned off and on.
  • Page 194 Di-C1 Training Replacement Toner hopper unit During reassembly, pour some carrier (8g) into the hopper. » A small bottle of carrier is provided with the new toner hopper spare part as an accessory. It contains 8g of carrier. » Follow the procedure in the manual carefully. The shutter comes off easily after the inner cover has been removed.
  • Page 195 Di-C1 Training Di-C1 TRAINING COPIER ENGINE TRANSFER Slide 195 In this section, the image transfer, paper transfer, and paper separation mechanisms will be described.
  • Page 196 Di-C1 Training Paper ITB Drive Overview Image Transfer Transfer Roller Belt (ITB) Roller ID Sensors Direction of ITB Rotation Image ITB Cleaning Unit Drum (K) Transfer Roller (K) For each colour, the image transfer roller pulls the developed toner image off the drum.
  • Page 197 Di-C1 Training ITB Lock Lever To release the ITB from the K drum, you must turn the image transfer belt unit lock lever clockwise before you remove the unit. If you do not do this, you will damage the K drum.
  • Page 198 Di-C1 Training ITB Drive Image Transfer ITB Drive Belt (ITB) Motor ITB Drive Roller This motor drives the transfer belt and its cleaning unit at the same time. Slide 198 Drive for the transfer belt cleaning unit is shown in more detail later in this...

  • Page 199: Speed Control

    Di-C1 Training Speed Control Encoder The encoder monitors the belt speed. The machine adjusts the motor speed, based on the output from the encoder. Slide 199 The speed of the belt depends on the process speed (see ‘Process Speeds’ in the Machine Overview section of the course).
  • Page 200 Di-C1 Training Current Supplied to the ITB Image Transfer Rollers Grounding Roller The image transfer rollers pull the toner off the drum. The grounding roller grounds the transfer belt. The terminals from the high voltage supply board (HVPS- TTS) come in at the rear of the ITB unit.

  • Page 201: Transfer Belt Cleaning

    Di-C1 Training Transfer Belt Cleaning The lubricant application roller applies lubricant to the belt. The blade scrapes this toner off the belt. This toner falls onto a coil in the collection bottle. At 0.5 seconds after the end of the job, the...
  • Page 202 Di-C1 Training Waste Toner Collection From the Image Transfer Belt Waste toner from the transfer belt falls into a coil. The ITB drive motor drives this coil through some gears at the front of the ITB unit. This coil moves the waste toner to the toner collection bottle.
  • Page 203 Di-C1 Training Waste Toner Bottle Near-Full Sensor Actuator When the bottle is almost full, the screw pushes against the toner while it turns, and this causes the end of the coil to push the actuator into the sensor. At this time, the machine detects ‘near-full’.
  • Page 204 Di-C1 Training ITB Contact and Release - 1 ITB Contact Motor ITB Contact Sensor The belt always contacts the K drum. To move the belt away from the K drum, turn the release lever clockwise. Do this to remove the transfer belt unit, or you will damage the K drum.
  • Page 205 Di-C1 Training ITB Contact and Release - 2 ITB Contact Motor ITB Contact Sensor The motor moves the left end of the belt up and down, through a cam. Up: The belt contacts the K drum only Down:The belt contacts all four drums The sensor detects when the belt contacts all four drums.
  • Page 206 Di-C1 Training ITB Contact and Release - 3 ITB Contact Motor Gear ITB Contact Sensor If a power failure occurs with the belt touching all 4 drums, the belt stays in this position, and you cannot remove the ITB. Open the exit tray cover, then turn the gear or cam of the transfer belt unit until the belt is fully raised.

  • Page 207: Paper Transfer Unit

    Di-C1 Training Paper Transfer Unit This unit contains the paper transfer roller and the discharge plate. Discharge Plate Paper Transfer Roller (PTR) Slide 207 The discharge plate removes charges from the paper, and this makes it easier to separate from the transfer belt.
  • Page 208 Di-C1 Training Discharge PTR Mechanism Plate The PTR rotates by friction with the transfer ITB Drive belt. Roller The ITB drive roller pushes the toner off the belt, and onto the paper. The PTR is grounded. It does not pull the toner off the belt, like in some models.
  • Page 209 Di-C1 Training PTR Contact Mechanism Sensor Motor Paper transfer roller contact motor: Moves the PTR into contact and away from the transfer belt, through a lever. Paper transfer roller HP sensor: Detects when the PTR contacts the transfer belt. Slide 209...
  • Page 210 Di-C1 Training PTR Contact Mechanism The PTR contacts the transfer belt at all times, except During line position adjustment (MUSIC) During process control Sleep mode » In standby mode, the PTR still contacts the transfer belt. When the power switch on the operation panel is »...
  • Page 211 Di-C1 Training Replacement – Image Transfer Unit (1) Image Transfer Belt Unit The ITB is in contact with the K drum before you turn the switch off. Take care not to damage the K drum. » To release the ITB from the K drum, you must turn the image transfer belt unit lock lever clockwise before you remove the unit.
  • Page 212 Di-C1 Training Replacement – Image Transfer Unit (2) Image Transfer Belt Unit, Image Transfer Belt If you will install a new ITB unit, set SP 3902-013 to 1 before you turn off the power switch. » If you do this, then the machine will reset the PM counter for the unit automatically, after you turn the power on again.
  • Page 213 Di-C1 Training Replacement – Image Transfer Unit (3) Image Transfer Belt The belt has a rim at the front and a rim at the rear. All the rollers in the ITB unit must be between these two rims. The rims must not be riding on the rollers.
  • Page 214 Di-C1 Training Replacement – Image Transfer Unit (4) Image Transfer Belt (continued) The white mark on the belt must be at the rear side. Slide 214 No additional notes...
  • Page 215 Di-C1 Training Replacement – Paper Transfer Unit Paper Transfer Roller Unit or Paper Transfer Unit If you will install a new unit, set SP 3902-018 to 1 before you turn off the power switch. » If you do this, then the machine will reset the PM counter for the unit automatically, after you turn the power on again.
  • Page 216 Di-C1 Training SP Modes – Paper Transfer Current for OHP SP2603-001 OHP current for black-and white Default settings: -15 μA (USA), -13 μA (other regions) SP2608-001 OHP current for full colour Default settings: -24 μA (USA), -20 μA (other regions)
  • Page 217 Di-C1 Training Di-C1 TRAINING COPIER ENGINE PAPER FEED Slide 217 In this section, the paper feed mechanisms in the copier will be described. The optional paper feed units will be described in separate sections.
  • Page 218 Di-C1 Training Overview Registration Rollers Trays 1 and 2, and bypass tray: Feed roller and friction pad system Tray 1 Tray 1 has belt assisted feed. Allows thick paper (up to 256 g/m ) to be fed. Capacity Tray 1 and 2: 250...
  • Page 219 Di-C1 Training Belt-Assisted Feed for Thick Paper Belt-assisted feed enables paper to feed though the sharp bend in the paper path. Previous design: Without belt assistance, the edge of the paper hits the roller and creates a paper jam. With belt assistance: The belt guides the paper to the rollers to take the paper smoothly.
  • Page 220 Di-C1 Training Drive – Trays 1 and 2 Paper Feed Motors Each tray has a motor. There are no paper feed clutches. If the tray is in the machine, the feed roller always touches the top sheet of paper. Slide 220...
  • Page 221 Di-C1 Training Drive - Bypass Feed Roller Motor The bypass motor drives the feed roller, through some gears. The cam at each end of the shaft moves the bottom plate up. This pushes the paper up against the feed roller.
  • Page 222 Di-C1 Training Tray Lift – Trays 1 and 2 A spring pushes up the tray bottom plate. Slide 222 No additional notes...
  • Page 223 Di-C1 Training Paper Size Detection – Trays 1 and 2 Paper Size Switch End Plate Actuator The sensor detects the paper size. The actuator position depends on the end plate position. Slide 223 The sensor functions as a tray set switch and a size detector.
  • Page 224 Di-C1 Training Paper Size Detection – Bypass Tray Paper Length Sensor Paper Width Sensor A length sensor is added. This helps the machine to distinguish between these pairs of paper sizes, which have the same width A4 SEF and A5 LEF A3 SEF and A4 LEF The sensor cannot distinguish between LT and LG SEF.
  • Page 225 Di-C1 Training Paper End Detection – Trays 1 and 2 Paper End Sensor Bottom Plate When there is no paper, the feeler drops into the slot in the bottom plate. Then the actuator enters the paper end sensor. Slide 225...
  • Page 226 Di-C1 Training Registration Registration Rollers The registration motor drives the registration rollers. Registration Motor Slide 226 No additional notes...
  • Page 227 Di-C1 Training Tray Lock - Front Lock Lever This lock prevents the tray from coming out during shipping. Pull the handle to release the lock. The lock lever is lifted when you pull the handle. Slide 227 No additional notes...
  • Page 228 Di-C1 Training Registration Paper Dust Collection Idle Roller Mylar Dust Container The mylar removes paper dust from the registration idle roller. Slide 228 No additional notes...
  • Page 229 Di-C1 Training Replacement Bypass paper width switch: Take care to install the switch correctly. After installation, test that the switch was installed correctly. There is a procedure in the manual. Friction pad: Make sure that the mylar does not go under the friction pad when reinstalling the friction pad.

  • Page 230: Cleaning The Registration Roller

    Di-C1 Training Cleaning the Registration Roller Clean the registration roller and registration idle roller with a damp cloth every 60 K. Never use alcohol to clean the registration roller. Slide 230 No additional notes...
  • Page 231 Di-C1 Training Size Detection – SP Modes SP 5181 Some paper sizes are almost the same and cannot be distinguished by the sensors. To select which size is detected, use SP 5181. SP 5112 Tray 2: If the user cannot select a non-standard paper size with the user tool, set this SP to 1.
  • Page 232 Di-C1 Training Di-C1 TRAINING COPIER ENGINE FUSING Slide 232 In this section, the fusing unit will be described.
  • Page 233 Di-C1 Training Overview Fusing Belt Pressure Roller Heating Roller Fusing Roller A fusing belt system is used. The heating roller and pressure roller contain lamps. The two lamps in the heating roller are in one assembly, and are removed together. One lamp heats the center and the other lamp heats the ends.
  • Page 234 Di-C1 Training Temperature Control Components Fusing Belt Pressure Roller Heating Roller Fusing Roller The following components control the temperature: Heating roller: One thermistor and two thermostats Pressure roller: Two thermistors and one thermostat At the front of the fusing unit: Thermopile...
  • Page 235 Di-C1 Training Temperature Control Components Thermostats Thermopile Thermistor Pressure Heating Roller Roller Thermostat Thermistors The following components control the temperature: Heating roller: One thermistor and two thermostats Pressure roller: Two thermistors and one thermostat At the front of the fusing unit: Thermopile Slide 235 Here is a three-dimensional drawing of the fusing unit.
  • Page 236 Di-C1 Training Fusing/Exit Drive The fusing/paper Motor exit motor drives the pressure roller and the fusing roller. The fusing belt drives the heating roller. Heating Roller Pressure Roller Paper Fusing Roller Slide 236 Paper passes vertically through the right side of the fusing unit, as shown in...

  • Page 237: Pressure Release

    Di-C1 Training Pressure Release Pressure Roller Pressure Levers The pressure levers apply the correct pressure from the pressure roller. When the cover is opened, the pressure is released, and paper jams can be removed easily. Slide 237 No additional notes...

  • Page 238: Fusing Temperature Control

    Di-C1 Training Fusing Temperature Control The fusing temperatures for each paper type and operating mode are set with SP 1105. Slide 238 No additional notes...
  • Page 239 Di-C1 Training Fusing Temperature Corrections Corrections for ambient temperature (SP 1112) If the room temperature is below 17 °C, the heating roller temperature is increased by 5 °C. If the room temperature is above 30 °C, the heating roller temperature is decreased by 5 °C.

  • Page 240: Overheat Protection

    Di-C1 Training Overheat Protection Power to the fusing lamp is cut if the machine detects that the temperature at the heating roller or pressure roller is 250 °C or more. SC 544, 554, 564, or 574 will occur. SC codes related to overheat protection...
  • Page 241 Di-C1 Training Fusing Unit Replacement (1) If you will install a new fusing unit, set SP 3902- 014 to 1 before you turn off the power switch. If you do this, then the machine will reset the PM counter for the unit automatically, after you turn the power on again.
  • Page 242 Di-C1 Training Fusing Unit Replacement (2) Lock Levers When installing the fusing unit: Make sure that the both lock levers are locked before closing the duplex unit. Otherwise, these lock levers can be broken. Slide 242 No additional notes...
  • Page 243 Di-C1 Training Lubrication When reassembling the fusing unit When replacing the fusing roller, you have to apply Barrierta S552R to the following places. Slide 243 No additional notes...
  • Page 244 Di-C1 Training Replacement Turn off the main switch and wait until the fusing unit cools down before beginning any of the procedures in this section of the machine. The fusing unit can cause serious burns. When cleaning the thermopile, wait until the fusing unit has completely cooled down.
  • Page 245 Di-C1 Training Cleaning at 60k The following must be cleaned every 60k. Entrance guide plate (cloth moistened with alcohol) Stripper plate (cloth moistened with alcohol) Exit guide plate (cloth moistened with alcohol) Pressure roller (cloth moistened with alcohol) Heating roller thermistor (dry cloth)
  • Page 246 Di-C1 Training Cleaning the Entrance Guide Plate Clean at these locations. Slide 246 No additional notes...
  • Page 247 Di-C1 Training Cleaning the Stripper Plate Paper dust attaches to the stripper plate, as shown above. Slide 247 No additional notes...
  • Page 248 Di-C1 Training Cleaning the Exit Guide Plate Clean at these locations. Slide 248 No additional notes...
  • Page 249 Di-C1 Training SP Modes 1106: Displays the temperatures inside the fusing unit 1801-007: Fusing motor speed adjustment Fusing motor speed can be adjusted in 0.01% steps. Normally, it is at –0.4%. The fusing motor normally turns slower than the transfer roller, so there is some slack between the fusing unit and the PTR.
  • Page 250 Di-C1 Training Di-C1 TRAINING COPIER ENGINE PAPER EXIT Slide 250 In this section, the paper exit mechanism will be described.
  • Page 251 Di-C1 Training Exit to the One-bin Paper Exits Tray or Finisher There are four exits Exit to the Side Tray Exit to the Standard Tray or Shift Tray Exit to the Duplex Unit In from the Fusing Unit Slide 251...

  • Page 252: Junction Gates

    Di-C1 Training Junction Gates There are three junction gates. Junction Gates Slide 252 No additional notes...
  • Page 253 Di-C1 Training Junction Gate – To the Standard Tray To feed paper to the standard tray, the solenoid for junction gate 1 is off. This is the default position. Junction Gate Slide 253 This diagram shows the junction gate configuration when paper goes to the...
  • Page 254 Di-C1 Training Junction Gate – To the Standard Tray Paper Exit Rollers Fusing/ Exit Motor The fusing/exit motor drives the paper exit rollers. There is no tray full sensor for the standard exit tray. Slide 254 Here is a three-dimensional view of the mechanism.
  • Page 255 Di-C1 Training Inverter Junction Gate – To the Inverter Rollers Junction To feed paper to the Gate 2 inverter tray, junction gate 1 blocks the exit path to the standard tray. The inverter rollers feed the paper up to the...
  • Page 256 Di-C1 Training Junction Gate – To the Inverter Duplex Inverter Motor Inverter Rollers The inverter motor drives the inverter rollers. Slide 256 Here is a three-dimensional view of the mechanism.
  • Page 257 Di-C1 Training Junction Gate – To the Side Tray To feed paper to the side tray, junction gate 1 blocks the exit path to the standard tray. The paper goes to the inverter tray, in the same way as for duplex mode.
  • Page 258 Di-C1 Training Di-C1 TRAINING COPIER ENGINE DUPLEX Slide 258 In this section, the duplex mechanism will be described.
  • Page 259 Di-C1 Training Inverter Overview To print on the second Inverter side, the machine feeds Rollers the paper up to the inverter. The inverter rollers then Standard reverse feed, and the Output Tray paper goes to the duplex unit. Fusing Unit...
  • Page 260 Di-C1 Training Duplex Upper Duplex Entrance Drive Motor Sensor Three motors control the rollers. Duplex inverter motor (explained previously) Duplex upper motor Duplex lower motor Two sensors control the paper feed timing and detect jams. Duplex entrance sensor Duplex exit sensor...
  • Page 261 Di-C1 Training Duplex Specifications Paper weight range: 60 – 105 g/m Paper size range: A3/DLT – A5 LEF Duplex speed: 25 cpm (A4/LT LEF, BW/FC) For the 20 cpm models, duplex speed is also 25 Cannot make duplex outputs from the bypass tray.
  • Page 262 Di-C1 Training Interleaving (1) Slide 262 The next two slides show how interleaving works in this machine.
  • Page 263 Di-C1 Training Interleaving (2) Slide 263 No additional notes...
  • Page 264 Di-C1 Training Di-C1 TRAINING COPIER ENGINE OPTIONAL AUTOMATIC DOCUMENT FEEDER (D366) Slide 264 PURPOSE OF THIS SECTION This optional unit will be described. It is similar to the ADF used with the D023 series copiers.
  • Page 265 The inverter unit lets the user make copies of two-sided originals. It stacks the originals in the correct order after scanning. There is a stamp for use with the Di-C1 fax unit (all models), or for scanning (Di-C1a/c only). This stamp is built-in, not optional.
  • Page 266 Di-C1 Training Components Study the component layout diagrams. Slide 266 Note the functions of the following components: Original sensor: During one-to-one copying, copy paper is fed to the registration roller before scanning, to increase the copy speed. The sensor monitors the stack of originals in the feeder, and detects when the trailing edge of the last page is fed in.

  • Page 267: Original Size Detection

    Di-C1 Training Original Size Detection Length Sensors Width Sensors Four width sensors, and three length sensors Width sensor: Photointerrupters Length sensors: Reflective photosensors Slide 267 D366 Service Manual, Detailed Section Descriptions, Basic Operation, Original Set and Size Detection The table in the service manual shows the sizes that the machine detects for each output.
  • Page 268 Di-C1 Training Original Size Detection – SP Modes 5126: Determines which F size is detected 6016: Determines how the machine interprets width/length sensor output for paper sizes that are almost the same. Slide 268 Make sure that the class is familiar with the table of sensor output vs original size.
  • Page 269 Di-C1 Training Mixed Original-Length Mode Width detection: Same as for normal mode Length detection: Done for each sheet As a result, scanning is slower if the user selects mixed size mode To detect length, the machine counts transport motor pulses from registration-sensor-on until...

  • Page 270: Pick-Up And Separation

    Di-C1 Training Pick-up and Separation Feed Clutch Feed Motor Pick-up Feed Roller Belt Separation Roller Pick-up solenoid: Lifts the original table, to lift the originals to the pick-up roller Feed motor: Controls the rollers Feed clutch: Controls the pick-up roller and feed belt...

  • Page 271: Skew Correction

    Di-C1 Training Skew Correction Skew Feed Motor Correction Sensor Skew Correction Roller First, the feed motor rotates forwards: The feed belt feeds the original, but the skew correction roller does not turn. The leading edge of the original hits the skew correction roller, and this removes any skew in the original.
  • Page 272 Di-C1 Training Original Transport and Feed-out Transport Exit Motor Roller Registration Roller The transport motor drives the registration and exit rollers. Slide 272 No additional notes...
  • Page 273 Di-C1 Training Original Transport and Feed-out Single-sided DF Exposure Glass Transport motor: Feeds the original through the scanner Motor speed is set by the reproduction ratio Slide 273 D366 Service Manual, Detailed Section Descriptions, Basic Operation, Original Transport and Exit The machine scans the original through the DF exposure glass.
  • Page 274 Di-C1 Training Original Transport and Feed-out Double-sided 1 Junction Gate Inverter Table When the original exit sensor detects the leading edge, the junction gate opens and the original goes to the inverter table. Slide 274 The main points are on the next 4 slides.
  • Page 275 Di-C1 Training Original Transport and Feed-out Double-sided 2 Inverter Roller When the paper is in the inverter table, the feed motor changes direction and the inverter roller feeds the original into the ARDF again. Slide 275 No additional notes...
  • Page 276 Di-C1 Training Original Transport and Feed-out Double-sided 3 Inverter Table DF Exposure Glass The rear side is scanned The original is fed to the inverter table again The page goes to the inverter mechanism again. This stacks the pages of the original in the correct order.
  • Page 277 Di-C1 Training Original Transport and Feed-out Double-sided 4 Exit Tray The page is fed in from the inverter table and out to the exit tray. Slide 277 No additional notes...
  • Page 278 Di-C1 Training Stamp (Fax and Scanner) This is used in fax mode or in scanner mode. The original is stamped if the original was sent. For memory transmission and scanning, the original is stamped if it is stored successfully. SP 6-010: This setting adjusts the stamping position.
  • Page 279 Di-C1 Training Dust Detection (SP 4020) This function checks the ADF exposure glass for dust that can cause black lines in copies. If dust is detected, a message is shown on the operation panel, but the machine does not stop.
  • Page 280 Di-C1 Training SP Modes 4-020: Dust check SP 7-852: Shows the number of times that the machine detected dust on the ADF. 6-006: Registration 6-009: ADF free run 6-010: Stamp position adjustment (in the sub- scan direction only) Slide 280 4-020: This function checks the narrow scanning glass of the ADF for dust that can cause black lines on copies.
  • Page 281 Di-C1 Training Di-C1 TRAINING COPIER ENGINE ONE-TRAY PAPER TRAY UNIT (D425) Slide 281 PURPOSE OF THIS SECTION The mechanisms in the optional one-tray paper feed unit will be described. It is similar to the paper tray unit used with the Kir-C3 series.

  • Page 282: Paper Feed And Separation

    Di-C1 Training Paper Feed and Separation Feed roller and friction Paper feed motor: Drives the feed roller. There is no clutch. Slide 282 There are two motors, one to lift the bottom plate and one to drive the rollers. There are no clutches.
  • Page 283 Di-C1 Training Paper Lift - Engaging the Shafts The two shafts engage when the tray is pushed into the machine. One shaft lifts the stack The other shaft controls the paper feed pressure Slide 283 This mechanism has two purposes: To lift the stack to the paper feed height.
  • Page 284 Di-C1 Training Paper Lift - Pressure Application Lift Sensor Main Pressure Spring Secondary Pressure Spring Lift Motor Bottom Plate Pressure Lever When the lift sensor is activated, the lift motor reverses briefly to reduce the feed pressure Slide 284 This slide shows how the tray is lifted.

  • Page 285: Paper End Detection

    Di-C1 Training Paper End Detection Paper end sensor feeler: Falls through a slot in the bottom plate when there is no paper. Slide 285 No additional notes...

  • Page 286: Paper Height Detection

    Di-C1 Training Paper Height Detection Bottom Plate Pressure Lever Paper Height Sensors Bottom plate pressure lever: Moves as paper is used up Slide 286 Note that these sensors are not used unless the optional printer controller has been installed. Then the current status can be viewed from the driver.

  • Page 287: Paper Size Detection

    Di-C1 Training Paper Size Detection The tray is a universal tray. Paper size sensors: Detect the paper length The position of the sensor actuator is controlled by the position of the end fence Slide 287 Only the length is detected directly.

  • Page 288: Side Fences

    Di-C1 Training Side Fences Screw The side fences have stoppers to prevent them bending when a full tray is pushed in too strongly Slide 288 If the tray is full of paper and it is pushed in strongly, the fences may deform or bend.

  • Page 289: End Fence

    Di-C1 Training End Fence End fence The bottom plate lifts as the paper is used up The fence is connected to the bottom plate, and it moves forward when the bottom plate lifts. This keeps the edges of the paper in the stack tidy.
  • Page 290 Di-C1 Training Di-C1 TRAINING COPIER ENGINE TWO-TRAY PAPER TRAY UNIT (D331) Slide 290 In this section, you will study the mechanisms of the optional paper feed unit. This is the same as the paper tray unit that is used with the Pr-C1.
  • Page 291 Di-C1 Training Paper Feed and Separation Feed roller and friction Paper feed motor: Drives the feed roller The appropriate paper feed clutch turns on to transfer drive from the motor to the rollers in the required tray. The relay clutch...
  • Page 292 Di-C1 Training Paper Lift - Engaging the Shafts The two shafts engage when the tray is pushed into the machine. One shaft lifts the stack The other shaft controls the paper feed pressure Slide 292 This mechanism has two purposes: To lift the stack to the paper feed height.
  • Page 293 Di-C1 Training Paper Lift - Pressure Application Lift Sensor Main Pressure Spring Secondary Pressure Spring Lift Motor Bottom Plate Pressure Lever When the lift sensor is activated, the lift motor reverses briefly to reduce the feed pressure Slide 293 This slide shows how the tray is lifted.
  • Page 294 Di-C1 Training Paper End Detection Paper end sensor feeler: Falls through a slot in the bottom plate when there is no paper. Slide 294 No additional notes...
  • Page 295 Di-C1 Training Paper Height Detection Bottom Plate Pressure Lever Paper Height Sensors Bottom plate pressure lever: Moves as paper is used up Slide 295 Note that these sensors are not used unless the optional printer controller has been installed. Then the current status can be viewed from the driver.
  • Page 296 Di-C1 Training Paper Size Detection Both the trays are universal trays. Paper size sensors: Detect the paper length The position of the sensor actuator is controlled by the position of the end fence Slide 296 Only the length is detected directly.
  • Page 297 Di-C1 Training Size Detection – SP Modes SP 5181 Some paper sizes are almost the same and cannot be distinguished by the sensors. To select which size is detected, use SP 5181. » Tray 3: SP 5181 009 to 012 »...
  • Page 298 Di-C1 Training Side Fences Screw The side fences have stoppers to prevent them bending when a full tray is pushed in too strongly Slide 298 If the tray is full of paper and it is pushed in strongly, the fences may deform or bend.
  • Page 299 Di-C1 Training End Fence End fence The bottom plate lifts as the paper is used up The fence is connected to the bottom plate, and it moves forward when the bottom plate lifts. This keeps the edges of the paper in the stack tidy.
  • Page 300 Di-C1 Training Di-C1 TRAINING COPIER ENGINE SHIFT TRAY (D428) Slide 300 In this section, you will study the mechanisms of the optional shift tray. This unit is similar to the unit that is used in the Athena-C1/C2.
  • Page 301 Di-C1 Training Overview The shift tray is similar to an output tray, but it sorts outputs into different stacks To do this, it moves the tray from side to side. This is called 'shift sorting' and it is faster than rotation sorting.

  • Page 302: Basic Operation

    Di-C1 Training Basic Operation Tray Cover The tray cover moves from side to side The square platform on the disk goes into the groove on the bottom of the tray It is off centre and loosely connected, so the disk can rotate about...

  • Page 303: Tray Shift

    Di-C1 Training Tray Shift Motor Sensor The tray shift motor turns the central disk The shaft is at the centre of the disk The sensor on the control board detects when the tray is moved fully to the left or right Slide 303 The tray motor moves the tray from side to side.
  • Page 304 Di-C1 Training Di-C1 TRAINING COPIER ENGINE ONE-BIN TRAY (D426) Slide 304 In this section, you will study the mechanisms of the optional one-bin tray. This unit is similar to the unit that is used in the Athena-C1/C2.
  • Page 305 Di-C1 Training Overview This unit adds an output tray. It does not replace the tray that is supplied with the machine. It is not a sorter, because the tray and/or the rollers do not move from side to side. With more than one output tray, the user can (for example) send copy-mode outputs to the standard output tray, and fax-mode outputs to the 1-bin tray.
  • Page 306 Di-C1 Training Components The main motor in the copier operates the tray. There is no motor in the tray. The junction gate solenoid in the paper exit mechanism of the main copier sends paper to this tray. The paper sensor in the one-bin tray checks if there is paper in the tray.
  • Page 307 Di-C1 Training LED on the One-bin Tray One-bin Tray This LED lights when the one-bin Standard tray has an Output Tray output in it This LED lights when an output arrives on the one-bin tray. The one-bin tray is an optional device.
  • Page 308 Di-C1 Training Di-C1 TRAINING COPIER ENGINE SIDE TRAY (D427) Slide 308 In this section, you will study the mechanisms of the optional side tray. This unit is new.
  • Page 309 Di-C1 Training Overview The side tray is an additional output tray. This can be installed when the 500-sheet finisher is installed, so that the user can (for example) send copy-mode outputs to the finisher tray, and fax-mode outputs to the side tray.
  • Page 310 Di-C1 Training Drive Side Tray Side Tray Motor Exit Rollers The side tray motor drives the side tray exit rollers. Slide 310 No additional notes...
  • Page 311 Di-C1 Training Side Tray Feed-out to the Side Tray Exit Sensor Side Tray Inverter Junction Gate Junction Gate Side Tray Gate Solenoid The paper pushes the inverter junction gate open. The gate is normally closed by spring tension. After the trailing edge of the paper passes the inverter junction gate, the gate closes.
  • Page 312 Di-C1 Training Di-C1 TRAINING COPIER ENGINE INTERNAL FINISHER (D429) Slide 312 In this section, you will study the mechanisms of the optional 500-sheet finisher. This finisher has some similarities with the finisher for the AT-C1, but a punch unit is added.

  • Page 313: General Layout

    Di-C1 Training Optional General Layout Pick-up Unit Punch Unit Output Tray Jogger Tray Stapler Stack Height Detection Lever The stapler is built-into the finisher. There is an optional punch unit. Slide 313 The output tray moves down when the stack gets thicker.
  • Page 314 Di-C1 Training Drive Layout Pick-up Roller Motor Paper Transport Motor Pick-up Roller Transport Rollers Paddle Roller Belt Roller Unit Inverter Roller Slide 314 The pick-up roller motor can turn forward or in reverse. This is necessary because the pick-up roller feeds paper back into the jogger tray, and forward...
  • Page 315 Di-C1 Training Finisher Modes Straight feed-out Paper goes directly to the output tray without sorting or stapling Shift sorting Odd-numbered sets (set 1, 3, 5, etc): The front fence jogs the output, and the printout moves to the rear. Even-numbered sets (set 2, 4, 6, etc): The rear fence jogs the output, and the printout moves to the front.

  • Page 316: Paper Feed Paths

    Di-C1 Training Straight Feed-out Paper Feed Paths Inverter Junction Gate Stapling/Shift Sorting Inverter Path (Duplex Mode) There are three feed paths, as shown above. If duplex mode is selected, the paper is fed below the finisher, inverted, and fed back into the machine through the duplex unit.
  • Page 317 Di-C1 Training Pick-up Straight Feed-out Entrance Sensor Roller Unit Pick-up Roller When the entrance sensor detects the leading edge of the paper, the pick-up roller unit is lowered from its home position. The pick-up rollers feed the paper to the output tray.
  • Page 318 Di-C1 Training Pick-up Shifting and Stapling (1) Roller Unit Top diagram: At first, the pick- Pick-up up roller unit stays up. Roller Middle diagram: When the trailing edge is almost out of the finisher, the pick-up roller Paddle unit moves down until the...
  • Page 319 Di-C1 Training Shifting and Stapling (2) Belt Roller Top diagram: The pick- Unit up roller unit moves down to send the next sheet to the jogger tray. Bottom diagram: When Idle Gear the stack is complete, the belt roller solenoid...
  • Page 320 Di-C1 Training Shifting and Stapling (3) After the stack is fed out, the belt roller unit returns to its home position (up). Paddle The paddles on the Roller paddle roller adjust the paper stack on the output tray. Paddle Roller...

  • Page 321: Inverter Mode

    Di-C1 Training Junction Gate Inverter Mode Solenoid Junction Gate Entrance Sensor When the entrance sensor detects the leading edge, the inverter junction gate solenoid turns on and the inverter junction gate opens the path to the inverter. The inverter roller feeds...
  • Page 322 Di-C1 Training Inverter Mode Inverter Roller Solenoid The inverter roller in the Idle Roller main machine feeds the paper to the duplex unit. The inverter roller in the finisher cannot rotate in reverse Because of this, the inverter roller solenoid...
  • Page 323 Di-C1 Training Jogging Jogger Fences Jogger Motors Stapler Jogger HP Sensors Jogger motors: Move the jogger fences. Done every page Jogger home position sensors: Detect when the jogger fences are at the home position again after jogging. Slide 323 No additional notes...
  • Page 324 Di-C1 Training Jogging Rear Front In standby mode, the jogger fences move away from the center. Standby In sort mode, the sets are separated as follows: Odd-numbered sets (set 1, 3, 5, etc): The front fence jogs the output. Sets 1, 3, 5...

  • Page 325: Stapler Unit Movement

    Di-C1 Training Stapler Unit Movement Stapler Stapler Unit Movement Motor Stapler Unit HP Sensor The stapler unit movement motor moves the stapler to the correct position for stapling. Slide 325 No additional notes...

  • Page 326: Stapling Positions

    Di-C1 Training Stapling Positions There are three stapling positions. One staple at the trailing edge (rear only) One staple at the trailing edge (front only) Two staples at the Rear Front trailing edge (front and rear) Slide 326 No additional notes...
  • Page 327 Di-C1 Training Disabling the Stapler Stapler Safety Sensor There are three fences in the stapler path. The stapler must not staple these fences. To disable the stapler, an actuator in the stapler is pushed into the stapler safety sensor when the stapler is at one of these fences.
  • Page 328 Di-C1 Training Stack Height Detection Stack Height Stack height lever Sensor 1 solenoid: Moves the detection lever to the top of the stack Stack Height Stack height Detection Lever sensors: These make sure that the top of the stack is at the Stack Height correct height.
  • Page 329 Di-C1 Training Output Tray Drive Output Tray Motor Gear Output tray motor: Moves the output tray up or down if the top of the stack is not at the correct height Tray lower limit sensor: Tray Lower Limit Detects when the tray...
  • Page 330 Di-C1 Training Punch Slider Punch Unit - Overview Unit Punch Edge and Size Sensors Registration Motor Punch Motor The punch slider unit moves from side to side, to make sure that the punch holes are made at the correct location.
  • Page 331 Di-C1 Training Registration Punch Unit - Registration HP Sensor Registration Motor Paper Size Sensors Paper Edge Sensor When the paper comes from the main machine, the paper edge sensor detects the leading edge. The registration motor moves the slide unit towards the front, until the paper size sensor that corresponds to the paper size detects the rear edge of the paper.
  • Page 332 Di-C1 Training Paper Edge and Size Sensors Emitter Receiver 1: Paper size sensor for A3 2: Paper size sensor for DLT 3: Paper size sensor for B4 4: Paper size sensor for A4 5: Paper size sensor for 16K 6: Paper size sensor for B5...
  • Page 333 Di-C1 Training Punch Units There are four types: 2 holes 2 or 3 holes » The user can select 2-hole punching or 3-hole punching from the operation panel or the printer driver. 4 holes » There are two 4-hole types: for North Europe, and for other areas.
  • Page 334 Di-C1 Training Two-hole and Four-hole Punch Units Punch Guides Slider Plate Punch Hole Motor Punch The punch motor turns a cam. A pin moves along a helical groove in this cam, and this pin moves the slider plates to the front and to the rear (only one slider plate is visible in this drawing).
  • Page 335 Di-C1 Training Two-hole and Four-hole Punch Units These two sensors Rear Position control the Sensor positioning of the slider plates. Actuator When the actuator enters the rear limit position sensor, the machine detects that Home Position a hole has been Sensor punched.
  • Page 336 Di-C1 Training Two-hole and Four-hole Punch Units Punch Guide Hole Punch For the first sheet of paper, the punch motor moves the slider plate to the rear. The punch guide forces the hole punch to move down, to punch a hole in the paper.
  • Page 337 Di-C1 Training Two-hole and Three-hole Punch Unit Slider Plate Similar to the two-hole and four-hole punch units, except: To punch two holes, the slider plate moves to the front To punch three holes, the slider plate moves to the rear.
  • Page 338 Di-C1 Training Three-hole Punching Punch Guide Hole Punch For the first sheet of paper, the punch motor moves the slider plate to the rear. The punch guide forces the hole punch to move down, to punch a hole in the paper.
  • Page 339 Di-C1 Training Two-hole Punching For the first sheet of paper, the punch motor moves the slider plate to the front. The punch guide forces the hole punch to move down, to punch a hole in the paper. The punch motor then changes direction until home position is detected again.
  • Page 340 Di-C1 Training Punch Waste Hopper Full Detection Actuator Punch Hopper Full Sensor Agitator Plate An actuator is attached to the rear edge of the agitator plate. This plate keeps the punch waste in the hopper level. When the punch motor rotates forward and in reverse to punch the paper, the agitator plate is also moved from right to left.
  • Page 341 Di-C1 Training Replacement Before you remove the covers from the finisher, you must remove the finisher from the machine. Slide 341 No additional notes...
  • Page 342 Di-C1 Training SP Modes Related to this Finisher SP6101: Stapling position SP6102: Punch position (sub scan) SP6104: Punch position (main scan) Slide 342 No additional notes...
  • Page 343 Di-C1 Training Di-C1 TRAINING COPIER ENGINE MAINTENANCE Slide 343 No additional notes...
  • Page 344 Di-C1 Training PM cycle: 60K and 150 K 60k: Drum unit, PCDU toner collection bottle, transfer belt cleaning unit assembly (includes a waste toner bottle) » At the same time, clean the area around the entrance sheet of the development unit. Also, in the fusing unit, clean the entrance and exit guides, the stripper plate, and the pressure roller.
  • Page 345 Di-C1 Training New Unit Detection For the following units, there is a new unit detection mechanism. It is not necessary to reset PM counters. PCDU Development unit only (not the complete PCDU) PCDU Toner Collection Bottles (if full or near-full)
  • Page 346 Di-C1 Training PCDU, PCDU Toner Collection Bottle PCDU This contains the drum unit and the development unit. The development unit contains the new unit detection mechanism for the PCDU. So, if you replace the PCDU, or the development unit only, the machine detects the new unit automatically and resets the counters.
  • Page 347 Di-C1 Training PM Counter Reset If you change the following parts, you must set the following SPs to 1 before you turn the machine power off. Development Unit only: 3902-001 (K), -002 (C), -003 (M), -004 (Y) Drum Unit only: 3902-009 (K), -010 (C), -011 (M), -012 (Y)
  • Page 348 Di-C1 Training After PM Do the ACC procedure. User Tools > Maintenance > ACC > Copier > Start User Tools > Maintenance > ACC > Printer > Start > Test Patterns 1, 2, and 3 Do the forced line position adjustment First do SP2-111-3 (Mode c).

  • Page 349: Service Maintenance - Cleaning

    Di-C1 Training Service Maintenance - Cleaning The service manual shows which parts of the machine and optional equipment must be cleaned when you visit the machine. The cleaning tool for the dust shield glass is stored in the front cover, as shown below.
  • Page 350 Di-C1 Training Important Notes to Remember for Slide 350 No additional notes...
  • Page 351 Di-C1 Training Drum Unit When installing the new drum unit : - Clean around the entrance sheet of the development unit New unit set & PM counter reset item Drum Unit K,C,M,Y SP3-902-009 to -012 Slide 351 No additional notes...

  • Page 352: Fusing Unit

    Di-C1 Training Fusing Unit When reassembling the fusing unit When replacing the hot roller, you have to apply Barrierta S552R to the following places. Slide 352 No additional notes...
  • Page 353 Di-C1 Training Di-C1 TRAINING COPIER ENGINE TROUBLESHOOTING Slide 353 This section goes over the troubleshooting tools built into the machine. Explain that the troubleshooting section does not cover all possible problems. In the field, technicians will have to think for themselves and draw on their own experiences.

  • Page 354: Process Control Results

    Di-C1 Training Process Control Results ID sensor test: SP 3-325 000 = Front, Center, Rear e.g. 111 Successfully completed Process Control Self-Check Result: SP3-012 e.g. 11 Successfully completed Line Position Adjustment Result: 2-194-10~12 Slide 354 Service manual, Troubleshooting, Process Control Error Conditions Each of these SPs gives a result code.
  • Page 355 Di-C1 Training Image Defects at Regular Intervals If a defect occurs in the image at one of these intervals, the related component may be defective. Drum: 94.2 mm Fusing belt: 157.1 mm Development roller: 32 mm Paper transfer roller: 75 mm...

  • Page 356: Reset Procedures

    Di-C1 Training Reset Procedures Software Reset Either » Operation panel power switch off/on » Hold the # and . keys for 10 seconds User Tool Settings Reset Press ‘User Tools’. To reset the system settings user tools: Hold # and press ‘System Settings’, then press ‘Yes’.

  • Page 357: Paper Jam History

    Di-C1 Training Paper Jam History SP 7504 shows details on jams that occur in each section of the machine. SP 7507 can be used to show details on the 10 most recent jams. Slide 357 Service manual, Troubleshooting, Jam Detection...
  • Page 358 Di-C1 Training Service Mode Lock If the customer uses the security functions on the machine, the technician has two problems: The technician cannot get into SP mode If the technician turns the machine power off and on frequently during servicing, a user name and password must be input each time.

  • Page 359: Error Codes

    Di-C1 Training Error Codes SC Codes 4 levels of SC condition. Use SP 5810-1 to clear level A service call codes, then turn the main power off/on. Level D SC codes The machine can be set with SP 5875 to reboot automatically after 30 seconds if a level B SC code occurs.
  • Page 360 Di-C1 Training Card Save (1) This feature allows you to send print data files to an SD card in the service slot (slot 2 in this machine). The data is not printed. Card Save mode must be turned on with printer bit switch 1, bit 4.
  • Page 361 Di-C1 Training Card Save (2) Previously stored files on the SD card can be overwritten or left intact. After you enable this function with the printer bit switch, the following two user tools are added to the List/Test Print tab of the Printer Features user tools menu.
  • Page 362 Di-C1 Training SP Modes - Tests 2-109: Test pattern printing 4-301: APS sensor output test 5-803: Input tests 5-804: Output tests 6-007: ADF input tests 6-008: ADF output tests 6-120: Finisher input tests 6-121: Finisher output tests Slide 362 No additional notes...
  • Page 363 Di-C1 Training SP Modes - Counters 7-401: SC counter 7-403: SC history 7-502 to 7-506: Jam counters 7-507: Printer engine jam history 7-508: Original jam history 7-807: SC/jam counter reset Slide 363 No additional notes...
  • Page 364 Di-C1 Training SP Modes - Others 5-990: Parameter lists (SMC list printing) 7-801: ROM version display Slide 364 No additional notes...
  • Page 365 Di-C1 Training Di-C1 TRAINING COPIER ENGINE D432: Fax Option Type C2550 (for Di-C1-a/c) D433: Fax Option Type C2530 (for Di-C1L-a/c) Slide 365 No additional notes...

  • Page 366: General Specifications

    Di-C1 Training General Specifications Resolution: Standard: 8 x 3.85 lines/mm, 200 x 100 dpi Detail: 8 x 7.7 lines/mm, 200 x 200 dpi Fine: 8 x 15.4 lines/mm Super Fine (Di-C1a/c only): 16 x15.4 lines/mm, 400 x 400 dpi Super Fine: Optional Expansion Memory...
  • Page 367 Di-C1 Training General Specifications Data MH, MR, MMR, JBIG Compression: Protocol: Group 3 with ECM Modulation: V.34, V.17 (TCM), V.29 (QAM), V.27ter (PHM), V.21, V.8 (FSK) Data Rate: 33600/31200/28800/26400/24000/21600/ 19200/16800/14400/12000/9600/7200/4800/ 2400 bps Automatic fallback I/O Rate: With ECM: 0 ms/line...
  • Page 368 Di-C1 Training General Specifications Memory ECM: 128 KB Capacity: SAF: Standard: 4 MB With optional Expansion Memory: 28 MB (Di-C1a/c only)) Page Memory: Standard: 4 MB x 2 With optional Expansion Memory: 8 MB x 2 (Di-C1a/c only) Slide 368...

  • Page 369: Preventing Transmission To The Wrong Destination

    Di-C1 Training Preventing Transmission to the Wrong Destination If you want to prevent documents being sent to the wrong destination, you can configure the machine to do the following: Prompt users more than once for the destination » How many times will the user have to input the destination: User parameter switch 22, bits 7 to 4 (1 to 15 times) »...
  • Page 370 Di-C1 Training Replacement and Adjustment When you replace the FCU board, remove the MBU board from the old FCU board and install it on the new FCU board. Set the correct date and time with the User Tools: User Tools> System Settings> Timer Setting> Set...
  • Page 371 Di-C1 Training FACE3 (Fax Application Control Engine) Data compression and reconstruction (DCR) DMA control Clock generation DRAM backup control Ricoh Modem and NCU Circuit V.34, V.17, V.29, V.27ter, V.21, and V.8 Data transfer Line control Ringing signal/tone detection Slide 371...
  • Page 372 Di-C1 Training DRAM The 16 MB of DRAM is shared as follows. » SAF memory: 4 MB » Page memory: 4 MB for scanning, 4 MB for printing » Work area, cache: 4 MB Memory back-up A rechargeable battery backs up the SAF memory (DRAM) for 1 hour.
  • Page 373 2MB (16bit x 1MB) + 1MB (16bit x 512K) SRAM The SRAM for system and user parameter storage is backed up by a lithium battery (battery life: 5 years). » Di-C1: 256 KB » Di-C1L: 128 KB Slide 373 No additional notes...
  • Page 374 Di-C1 Training Memory back-up A lithium battery backs up the system parameters and programmed items in the SRAM, in case the base copier's main switch is turned off. Switch CN1: Switches the SRAM backup battery on/off. Slide 374 No additional notes...
  • Page 375 Di-C1 Training Stamp SP 6010: Adjusts the position of the stamp on the original in the sub scan direction. Slide 375 No additional notes...

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