HC5000 Tech

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Used to raise and move the machine for equipment
setup.

Maintenance Notes
Image adjustment utility software:

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

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

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

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

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

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

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

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

Used for cleaning rollers.
A4-size coated paper

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Removal of Covers

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Suction pump Ink pan
Reservoir
Suction chamber
Overflow tank sensor

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

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

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

Paper size detection sensor
Paper detection sensor
Paper width potentiometer

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

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

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

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

上中　下
2-2.F eed tray button

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

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

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

Paper feed tray lower safety SW

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

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

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

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

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

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

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

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


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

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

Paper width sensor
Face plates
Lock lever
Engagement of paper width

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

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

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

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

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

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

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

Elevator motor

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Paper volume sensor

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

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

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

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

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

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

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

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

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

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

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

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

ing pins
Remove these two screws.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

sensor (receive)

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

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

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

(7) Remove the lift gear unit.

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

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

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

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

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

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

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

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

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

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

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

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

M3x6 IT screw Side bracket

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Cable

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

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

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

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

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

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

Duplex belt lower
Hinge
Duplex belt upper

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

Side cover
Side cover
M4x8 RS-tight screw

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

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

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

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

19.Switchback unit lower

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

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

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

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

22.Main motor

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

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

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

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

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

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

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

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

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

26.Multiple feed sensor (receive)

Spring
Registration roller upper
Inner cover 1

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

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

sensor (receive)

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

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

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

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

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

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

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

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

28.Multiple feed sensor (send)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

5.Adjustment of backup roller position

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

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

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

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

7.Adjustment of the Registration roller upper

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

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

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

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

9.Adjustment of frame distortion compensation

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

on the both surfaces of the cleaning jig.

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

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

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

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

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

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

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

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

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

Print head (x24) Air open filter

Ink fuse solenoid
Suction chamber
Solenoid valve
ID unit 6.4mm
4mm
Ink cartridge
3mm
(x4)
Suction pump
12mm
Ink pan
4mm
Reservoir
(x4)
4mm
Tube joint
6.4mm (x8)
4mm
2mm Cleaning unit 4mm
Overflow tank
6.4mm
Solenoid valves
Pressure pump
Pressure chamber
Waste ink tank
The dimensions in the red colors represent inner
dimension of the ink and air tubes.
Schematic diagram of ink supply passages
7-3
HC50 00 20 05/12 (R ev. 3.0 )
1-2.Mai n pa rts of the i nk feed p assages
(1) Ink fuse solenoid

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

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

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

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

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

Compressed air flow
Pressure solenoid valve To pressure chamber

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

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

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

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

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

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

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

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

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

this area.
Nozzle surface
Avoid dust and scratches.

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

Head
head angle adjustment mechanism

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

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

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

To reservoir M
To ID solenoid valve (M)

To ID solenoid valve (Y)

To waste ink tank

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

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

solenoid valves on each reservoir
M

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

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

Suction head operation
Flow of waste ink drawn by suction head

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

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

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

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

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

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

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

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

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

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

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

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

on the Yellow Ink side.
Ink release bracket

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

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

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

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

the air open filter area

2.Receiver PCB

(2) Remove the ink cartridge from the ink cartridge holder from which the receiver PCB is to be
removed.
(3) Pull the ink cartridge holder slightly forward (two M3x6 IT screws).
* If the ink cartridge holder is pulled too much forward, the tubes from the ink pan may disconnect and
may result in ink leakage. Pay caution when pulling the ink cartridge holder forward.
M4x5 IT screw
Ink cartridge holder
M4x5 IT screw
(4) Disconnect the special cable from the Receiver PCB connection.
(5) Pinch the Receiver PCB holder in the direction of the arrow and pull out the PCB holder with the
Receiver PCB attached.
Special cable
7 - 29
HC50 00 20 05/12 (R ev. 3.0 )
(6) Detach the Receiver PCB from the PCB holder.
* When reinstalling the PCB holder unit, pay close attention not to touch hard against the ink tubes
nearby, as that may cause the tubes to partially disconnect, or in worst cases the ink tubes may come
loose and spill the ink.
* Make sure that the PCB is firmly inserted into the PCB holder and the PCB holder secured firmly onto
the ink cartridge holder.
Receiver PCB

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

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

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

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

color as an example.
Unhook the ink joint from the

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

bracket.
Enlarged view of the Yellow Ink reservoir tubing.

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

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

5.Pressure pump unit

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

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

Pressure pump unit
Motor connector Sensor connector
7 - 37
HC50 00 20 05/12 (R ev. 3.0 )
6.Pressure chamber

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

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

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

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

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

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

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

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

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

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

8.Print head
The print heads are very fragile and vulnerable to impact and shock. Pay attention to the following
when handing the print head.
* Do not drop the print head. The print head surface will be damaged, and the piezo mechanism will also be
damaged.
* Prevent the print head surface (the nozzle portion) from touching any surface after taking the head out of
the machine.
* Never lay anything on top of the print head.
* When transporting the print head, use the special print head shipment container in which a print head is put
in when ordered as a spare part, and place it in the container correctly.
* Avoid from hitting the nozzle surface against the print head carriage when installing the print head on the
machine.
* To prevent print head damage from static electricity, be sure to wear an antistatic wrist band when touching
print heads. If antistatic wrist band is not available, touch the machine metal frames firmly with both hands
before working to let the static electricity escape from the body.
(1) Confirm that the ink pan is positioned under the heads (if not, slide the ink pan under the heads
using Test Mode). Place paper on top of the belt to catch any ink that may drip from the heads.
(3) Remove the control panel together with the bracket and put the panel aside.
(4) Remove the control panel cable guide (beam).
(5) Pull out the duplex unit and detach it from the machine.
(6) Remove the carriage cover.
* Depending on the ink color, the Ink cartridge holder unit may have to be slid toward the paper feeding
side to access to the screws to remove the carriage cover.
(7) Remove the head ribbon cables from the head drive PCB for the print head to remove.
(8) Disconnect print head tube from the print head to remove.
* Be sure to close the valve before disconnecting the print head tube.
Disconnect other print head tubes if they interfere.
Valve closed Valve opened
7 - 43
HC50 00 20 05/12 (R ev. 3.0 )
(9) After removing the screws with washers, lift the head straight up (two M3x23 screws with wash-
ers).
The screw to be removed the first in removal.

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

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

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

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

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

9.Head drive PCB

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

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

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

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

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

(2) To remove the suction head, push it down gently and open the hook that holds it in place.
* Take care to prevent the spring from springing out.
* Do not widen the hook too much, as that may crack the hook.
* After attaching the suction head, check that the suction head does not lean.
If the suction head leans, remove it once and attach it back on again. If attached on correctly, the
suction head should elevate up-and-down freely when pushed down by finger.
* If the suction head leans, poor suction of ink is caused and ink may drip and fall from the print head,
and the suction head may fall off after hitting the print head.
Suction head
Spring
7 - 51
HC50 00 20 05/12 (R ev. 3.0 )
12.Cap
(1) Remove the cleaning unit.

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

13.Suction chamber

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

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

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

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

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

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

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

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

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

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

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

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

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

Using Test Mode [8.5.1.1 Voltage] and [8.5.1.3 AL type], select the replaced print head and enter
the values indicated on the print head, as shown above. Then press the Enter key to save the
new parameter settings in the NVRAM mounted on the ORIP PCB.
Download the saved parameters from the NVRAM onto the ORIP PCB as a backup by using
Test Mode [8.5.6.1 Store Adj. Config.].
7 - 61
HC50 00 20 05/12 (R ev. 3.0 )
1-2.Preparation for the image adjustment
Arrange the tools and instruments required to make the adjustment.
Head angle jig
Reference chart for scanner calibration
Notebook PC (commercially available) running

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

* The photograph shows the print head angle being

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

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

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

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

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

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

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

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

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

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

Adj. Pattern are
printed.
One copy of Margin

Adj. Pattern is
printed.

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

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

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

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

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

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

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

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

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

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

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

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

ment software.
- continues on next page -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Blank page
7 - 83
HC50 00 20 05/12 (R ev. 3.0 )

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

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

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

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

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

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

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

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

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

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

• Recommended drive voltage correction
(4) Fine adjustment pattern

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

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

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

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

horizontal single-color lines
Deviation of horizontal single-

color lines
Example of defective printing

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

horizontal multiple-color lines
Deviation of horizontal multi-

ple-color lines
Example of defective printing

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

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

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

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

The recommended AL type entered is incorrect or inappropriate.
The print head is incorrect.
• Check the recommended AL type on the Control panel and correct the setting.
and position).

< Deviation of horizontal single-color lines >
Deviation of horizontal sin-

gle-color lines
• Characteristics
When the printed image is positioned so that the paper transport direction is vertical, a
defect is visible in the horizontal lines of a single color of K, C, M, or Y printed by the defec-
tive head. The horizontal single-color lines printed by the misaligned head are slightly dis-
placed. This defect is produced continuously from the top of the page to the bottom and
appears in every print.

• Defective head angle adjustment or deviation of adjustment
• The vertical position parameter setting of the defective head on the Control panel does not
match printer conditions.
and position).
8 - 11
HC50 00 20 05/12 (R ev. 3.0 )
< D e v i a t i o n o f d o t s o n s i n g l e - c o l o r h o r i zo n t a l l i n e s
Deviation of horizon-
tal single-color lines
• Characteristics
When the printed image is positioned so that the paper transport direction is vertical, a
defect is visible in the horizontal single-color lines of K, C, M, or Y printed by the defective
head. When observed under a magnifying glass, the single-color horizontal lines printed by
the defective head consist of separate, distinguishable dots.

• Defective print timing in the paper transport direction
• The ink ejection timing parameters for the two heads in the defective head are incorrect.
and position).

< Deviation of horizontal multiple-color lines
Deviation of horizontal multiple-

color lines
• Characteristics
When the printed image is positioned so that the paper transport direction is vertical, there
is a 1-PEL multiple-color shift in horizontal lines composed of two colors from K, C, M, and
Y. This appears as a color irregularity in multiple-color horizontal lines.
When observed under a magnifying glass, the multiple-color horizontal lines printed by the
defective heads show displaced dots. This color shift occurs uniformly within the width of
the print head.

• Defective head angle adjustment or deviation of adjustment
• Defective print timing in the paper transport direction. The vertical position parameter set-
ting of the defective head on the Control panel does not match printer conditions.
and position).
8 - 13
HC50 00 20 05/12 (R ev. 3.0 )
< Deviation of vertical multiple-color lines
Deviation of vertical multiple-color lines
• Characteristics
When the printed image is positioned so that the paper transport direction is vertical, there
is a 1-PEL multiple-color shift in vertical lines composed of two colors from K, C, M, and Y.
This appears as a color irregularity in multiple-color vertical lines.
When observed under a magnifying glass, the multiple-color vertical lines printed by the
defective heads show displaced dots. This color shift occurs uniformly within the width of
the print head.

Lateral print timing problems relative to the paper transport direction. The horizontal posi-
tion parameter setting of the defective head on the Control panel does not match printer
conditions.
and position).

< V i s i b l e p ri n t d e n s i t y d i s c o n t i n u i t i e s a t h e a d j o i n t s i n h a l f - t o n e p ri n t i n g
Several types of
multiple-color half-tones
Characteristics
When the printed image is positioned so that the paper transport direction is vertical, print
density discontinuities are visible at the head joints in half-tone printing.
Vertical lines may have higher or lower density compared to surrounding areas. The defect
also appears as vertical white streaks.

An overlap occurs at the joint between two adjacent heads. Image adjustment performs
image processing to make this overlapping section less conspicuous. The overlap parame-
ter does not match printer conditions.
• Replace one of the problem-causing print heads (determine the defective print head by
checking the color and position).
8 - 15
HC50 00 20 05/12 (R ev. 3.0 )

CHAPTER 9: Paper receiving section
CONTENTS
9-1
HC50 00 20 05/12 (R ev. 3.0 )
Mechanisms
1.Basic mechanism
1-1.Ove rvi ew of m echani sm

After printing, paper is discharged into the V-shaped exit tray. The paper exit section features the fol-
lowing mechanisms for the neat stacking of discharged sheets.
Paper receiving tray fence

• Two side fences and one end fence aligns the papers on the paper receiving tray.
• These three paper fences feature an automatic slide function to adjust their positions to match
the size of the paper in use.
• The cushion on the end fence keeps discharged paper from bouncing back. The cushion plate is
manually adjustable on is vertical position on the end fence.
Paper-settling flaps
• The side fences are provided with a total of four paper setting flaps. These flaps move slightly
due to the weight of discharged paper, giving the paper a slight upward curl so that they stack
neatly in the exit tray.
• The paper-settling flaps can be stowed away by pulling the flap knobs up.
Paper fence HP button
• Pressing the paper fence HP button moves the exit paper fences to their preset positions.
• If there is no printed paper in the paper receiving tray, the three fences retract to their stowage
positions. If printed paper is found in the tray, the stopper and guides move to the paper retriev-
ing position set by user menu 4.8.4 (shifting guide).
• The user menu 4.8.4 (shifting guide) allows the user to select either only the side fences to move
or only the end fence to move, or all three fence to move when the button is pressed.
• The sensor checks whether any paper printed in the previous print job remains in the exit tray.
According to the sensor detection status, the fence position is determined at the start of new
printing job.
End fence cushion

Side fence
Paper stopper
Paper-settling flaps
Paper guides HP button
Paper-settling flap knob


Damper mechanism
• Since the paper receiving tray is heavy, the tray support sections on both sides are provided with
dampers to open the tray slowly and minimize the impact when the tray is opened from the
stowed condition.
Damper
Paper guide base SW

• The paper guide base switches are provided to detect the folded state of the three fences. The
fences slide only when all switches are activated (the fences are in upright condition).
• If any one of the fence is folded, the switch disables the fence from sliding and error message is
displayed.
Paper guide base SW for the side fence
Plate
When the fence is in the upright
position, the switch is activated.
Plate
Paper guide base SW for the end fence
When the fence moves to the upright position, the white

plate descends and presses on the actuator plate, activating
the switch. Actuator
9-3
HC50 00 20 05/12 (R ev. 3.0 )
2. Fence sliding mechanism
2-1.F ence slidi ng me chani sm

Side fence sliding mechanism
• The following mechanisms are provided for side fence sliding operations.
1) Side fence pulse motor: Drive power for sliding operations.
2) Side fence HP sensor: Detects the widest opened position.
3) Side fence limit sensor: Detects the narrowest position. Prevents overruns due to malfunc-
tions.
• The two side fences are operated by linked gears and belts the synchronized movement.
Side fence on the machine drive side Side fence on the operator side
Side fence HP sensor
Side fence limit sensor
Side fence pulse motor

Back stopper fence sliding mechanism
• The following mechanisms are provided for the paper stopper sliding operation.
1) End fence pulse motor: Drive power for the sliding operation.
2) End fence HP sensor: Detects the widest position.
3) End fence limit sensor: Detects the narrowest position. Prevents overruns due to malfunc-
tions.
End fence
(HC5000)
End fence limit sensor
End fence pulse motor End HP sensor
9-5
HC50 00 20 05/12 (R ev. 3.0 )
2-2.Slid ing operatio ns at the begi nning of the pri nt o pera tion
B a s i c o pe ra t i o n s
• The auto paper receiving tray section is electrically connected to the HC Control PCB on the
HC5000. The three fences move to the appropriate positions according to the paper size at the
beginning of a print operation.
• First, all three fences slide to the widest position detected by the HP sensors.
• The three fences then slides inward to accommodate the paper size detected by the paper guide
fences on the paper feed tray of the HC5000.
W h e n t h e re i s a p a p e r l e f t o n t h e r e c e i v in g t ra y a t s t a rt o f n e w p r i n t i n g j o b
• If there is a paper still detected on the paper receiving tray from the last printing job at the start of
a new printing job, the fences on the paper receiving tray stays at present position if the paper
size detected for the new print job is equal or smaller in size than the last printing job. If the
paper size for the new print job is detected to be larger in size than the last printing job, the three
fences on the paper receiving tray are widened in position to receive the larger paper size for the
new print job.
W h e n u s i n g n o n s t a n d a rd - s i z e p a p e r
• For nonstandard paper sizes (custom sized papers), the side fences on the paper receiving tray
slides to the paper width detected by the paper guides on the paper feed tray. The end fence on
the paper receiving tray stops either of the two positions - fully wide position or half-wide posi-
tion.
W h e n u s i n g p o s t c a r d - s iz e p a p e r
• For receiving postcard size papers, the end fence moves in first before the side fences to pre-
vent the side fences from blocking the inward movement of the end fence.
2-3.Other
• Fine adjustment of fence stop positions can be performed from the user menu.
• When thin paper, standard, thick paper, or custom paper is selected in the paper information set-
ting, the fences stop at the preset positions for the each paper registered. (The positions must
be preset by the test mode 5.9.1.60 and 5.9.1.61 by the serviceman.)
• If the machine fails to operate due to a problem in the auto paper receiving tray, the HC5000 still
can be operated by disconnecting the connecting cable between HC5000 and the receiving tray.

Disassembly
1.Paper receiving tray
1-1. Rem oving the paper receiv ing tray < d isasse mbly >
(1) Disconnect the electrical cord between the tray and HC5000.
(2) Remove one mounting screw each from the flanges on the damper units left and right.
(3) Holding the paper receiving tray so that it does not fall, remove the flanges.
(4) After the flanges are removed, the paper receiving tray can be lifted off from the machine.
Flange
9-7
HC50 00 20 05/12 (R ev. 3.0 )
1-2.Remo val of cov ers
(1) Remove the paper receiving tray from the machine.
< Re m o v a l >
(1) Remove the bottom metal cover (four M4x8 P-tight screws, three M4x8 binding screws).
(2) Remove the side fences and end fence from the tray (two M3x6 binding screws each).
(3) Separate the tray mechanism from the plastic cover (17 M4x8 P-tight screws).
Bottom cover
Side fences
End fence
Plastic cover

2.Side fence belt section
2-1. Rem oving the side fence belts

< Step 1 >
(1) Dismount the paper receiving tray from the machine.
(2) Remove the bottom metal cover from the tray.
< Step 2 >
(1) Detach the idler spring and loosen the tensioner.
(2) Remove the belt clamp (one M3x8 binding screw).
(3) Detach the clip and flange from the pulley and remove the belt.
< >
• The two side fences are mechanically linked when they slide, so where the belt clamp is
attached during the assembly is important.
With the sliders of both fences moved all the way toward the center, place a mark on the belt to
indicate the installation position of the belt clamp, and then mount the belt clamp.
Idler spring Side fence pulse motor
Belt clamp
Remove clip and flange from this pulley.
2-2. Rem oving the side fence pul se motor

(1) Free the wires and disconnect the motor connector.
(2) Detach the retaining ring and flange from the pulley and remove the pulley. (Be careful to avoid
dropping the pin located inside the pulley.)
(3) Dismount the motor (three M4x8 RS-tight screws).
9-9
HC50 00 20 05/12 (R ev. 3.0 )
3.Removing the end fence pulse motor and sensors
< Step 1 >

(1) Dismount the paper receiving tray from the machine.
(2) Remove the bottom metal cover from the tray.
(3) Separate the tray mechanism from the plastic cover.
< Step 2 >
Removing the end fence pulse motor

(1) Disconnect the connectors of the paper detection sensor and end fence limit sensor together
with the bracket.(Two M4x8 RS-tight screws)
(2) Free the pulse motor wires, disconnect the connector to the pulse motor and remove the pulse
motor (three M4x8 RS-tight screws).
Remove this plate first to allow the screwdriver to go in.
Removing the end fence HP sensor

(1) Disconnect the connector, remove the four screws, and dismount the end fence HP sensor
together with the bracket.

Adjustment
9 - 11
HC50 00 20 05/12 (R ev. 3.0 )

Co ntroll e r & powe r s uppl y un it
CH APT ER 10: Con trol ler & pow er supp ly uni t
CO N T EN T S
10 - 1
H C5 000 2 005/12 ( Rev. 3.0)
Mechanisms
1 . C o nt r o l l e r ( P S 7 R)
1-1. Summary
• The controller (PS7R), which is installed inside the machine base on the right, allows the execu-
tion of a print job, use of the touch panel (option), scanning of an original on the scanner
(option), or updating of the firmware.
• PS7R is connected to the ORIP PCB on the main unit via a USB cable, to the touch panel via a
serial cable, and to the touch panel LCD via a VGA cable.
• PS7R status can be checked with the three LEDs located on its front panel.
ERROR READY DATA (yel-

(red) (green) low)
1 x x x Power OFF
2 lit lit lit BIOS starting up
3 blinking blinking blinking LINUX starting up/shutting down
4 blinking / x blinking / x blinking / x RIP starting up *1
5 x lit x In standby
6 x lit blinking RIP, WRAPPER in processing operation
7 x lit lit Awaiting output
8 lit lit x / lit / blink- PS7R error (RIP-related error)
ing
9 blinking lit x / lit /blink- PS7R error (system-related error)
ing
10 blinking blinking blinking Test, Reset button pressed
• If the controller (PS7R) does not start up, disconnect the two connectors from the hard disk
drive, then check to see if the BIOS starts up.
• If the BIOS does not start up, replace the power supply unit or motherboard of the PS7R. If the
BIOS starts up normally, replace the hard disk drive.
<< Caution >>
• The controller (PS7R) has a built-in hard disk drive. Do not disconnect the power cord or turn off
the main power supply when it is operating.
• The hard disk drive is easily damaged by impact or vibration. Handle carefully during disassem-
bly and reassembly. (Handle it as carefully as a PC.)
• Handle the PS7R carefully, since it contains settings entered by the network administrator at the
customer’s site.
• PS7R uses a USB connection to the ORIP PCB. In normal operation, do not connect ORIP
PCB directly to a PC using this USB connection.
• Before removing or reinstalling the memory module or other components within PS7R, ground
yourself by touching the metal frame to prevent damages by the static electricity.

1-2. Other operations
Switches on the rear of PS7R.

1) TEST switch
• Keep pressing the TEST switch until a buzzer sound is heard will print out a system data
page and allow to see the system setting of the PS7R.
• For this print to come out, the machine must be in Print Ready condtion. Press the print
button on the HC5000 if the green LED is not lit.
• The printout is equivallent to the one printed out by using 5.6.1. menu on HC5000 opera-
tion panel.
2) RESET switch
• By keep pressing the RESET switch for a long time will clear the network setting to the
default condition. The three addresses will be initialized to 0.0.0.0 This new default
setting becomes effective once the PS7R power is turned OFF and turned back ON.
• Also the scanner functions and touch-panel calibration will be initialized.
• This RESET switch should not be pressed by mistake. Otherwise all the data, which are
initialized, need to be input again.
Turning the power ON and OFF

• When operating HC5000, prevent the crash on the controller (PS7R) by not turning OFF
the maini power switch of HC5000 directly.
• Turn the machine off by pressing the Soft-Switch on the operation panel first. Turning the
machine off by the Soft-Switch gives the signal to PS7R to shut down and let the software
of the PS7R to shut down in the correct way, like normal computers.
• If the main power switch on HC5000 needs to be turned OFF, turn off the machine using
the Soft-Switch first. After PS7R shuts down completely then turn OFF the main power
switch on the machine.
• In normal operating condition of the machine, the power ON and OFF is done by the oper-
ators using the Soft-Switch. The main power switch is normally left turned ON.
USB Dongle
• The controller (PS7R) has a USB Dongle connected to one of the USB ports. The USB
Dongle is a hardware key and it should never be misplaced.
10 - 3
H C5 000 2 005/12 ( Rev. 3.0)
2 . R em o v i n g th e co n t r o l l er ( P S 7R )
PS7R Controller
(1) Perform the shutdown procedure on HC5000 by first pressing the Soft-Switch, and then the
main power switch after the PS7R shuts down, unplug the power cord from HC5000.
(2) Remove the four screws and detach the right cover from the base of HC5000.
(3) Detach controller support bracket from HC5000 by removing one screw.
(4) Disconnect the power cord connected between the controller (PS7R) and the power supply unit
of HC5000.
(5) Disconnect the UTP cable, USB dongle, USB cable (connected to ORIP PCB), USB cable (con-
nected to scanner), VGA cable (touch panel LCD), and serial cable (touch panel) from PS7R
and remove the PS7R from HC5000.
Power cable
VGA cable(touch panel LCD)
Power control cable
UTP cable (LAN)
No conect USB Dongle
USB cable (scanner) USB cable (ORIP PCB)
< >
There are four USB ports. Make sure the connections are made to the correct USB ports during
assembly.
Refer to the next page for the cable connections on PS7R9000.

PS7R900 Controller
(1) Refer to the following sketchs for the connection of the cables to PS7R9000.
10 - 5
H C5 000 2 005/12 ( Rev. 3.0)
3 . D i sa ss em bl y a n d r ea ss em b l y o f c o n tr o l l e r ( P S 7 R )
(1) Dismount the controller (PS7R).

(2) Remove the two screws from the back panel and dismount the cover.
R em ov ing t he h ar d dis k dr i ve
Remove one screw, disconnect the two connectors, and dismount the hard disk drive. (Keep a record
of the serial number of the hard disk drive.)
R em ov ing t h e m em o r y mod u le
After touching the frame to release static electricity, release the locks on both sides of the DIMM and
dismount the DIMM.
R em o v ing t he m ot he r b oa rd
Disconnect the DIMM, power supply connector, HDD connector, panel connector, speaker connector,
and case fan connector, then remove the six screws to dismount the motherboard.

4 . P o w er s u p pl y
(1) Remove the rear right cover from the MTPF.

(3) Remove the suction pump unit.
* Note: 3. Refer to the section on the suction pump unit.
(4) Remove the cable clamps.
* Note: When removing the power supply unit, be careful of cable clamp interference.
Cable clamps
Suction pump unit
(5) Disconnect the Power cable to the controller.

(6) Disconnect the connectors as shown on the photographs bellow.
Connectors
Connector
(7) Remove the screws (two M4x8 screws with washers on the rear, and four M4x8 screws with
washers on the side).
10 - 7
H C5 000 2 005/12 ( Rev. 3.0)
Power supply unit Connector
M4x8 screws with washer
M4x8 screws with washer
(8) Pull out the power supply unit from HC5000.

Te s t m o d e
CHA PT E R 11: Te s t mo d e
CONTENTS
11 - 1
HC50 00 200 5/1 2 (Rev 3.0 )
Test m od e
1.Operation method
1-1.Startup and shutdown for Test mode

< S t a rt i n g m e t h o d >
(1) In normal mode (Print mode turned OFF), press the Menu key, (Up) key, and Enter key simulta-
neously for three or more seconds to display the password input screen.
(2) Enter the password.
(3) Test mode is added to the menu to allow operations in Test mode.
• The Normal mode and Test mode menus are active at the same time.
• When Test mode is active, the normal menu can also be used to enter settings.
< Shutdown method >
(1) Press the Menu key, (Up) key, and Enter key simultaneously for three or more seconds to dis-
play the password input screen.
(2) If incorrect password is entered, the machine will close the Test mode and enter Normal mode
standby status (Print mode turned OFF).
1-2.Ope rations in T est m ode

< Test mode menu >
• When Test mode is active, the following test items are added to the menu:
• Menu 4 Configuration
• Menu 5 Administration
• Menu 8 Check/Setting/Ady
• Menu 9 Test Pattern
• Menu 12 (Menu No. input)
• From the hierarchical menu, select and run a test item.
• Menu 12 is a check no. input menu for direct selection of a test item. The No. of each hierarchi-
cal menu layer with test items is shown as a check no.
< Types of Test modes >
Test mode offers the following specific test types (modes).
Individual unit check mode S • This mode is used to check the ON/OFF status of
(Sensor and switch check) sensors and switches.
• Buzzer activation is determined by the ON/OFF
status.
Individual unit check mode M • This mode allows ON and OFF operation of an
(Motor and solenoid check) individual unit such as a motor.
Group unit check mode U • This mode activates operation for a group of units
(group unit operation).
Data check mode C • This mode displays the values entered as data.
Settings mode D • This mode enables changes in system status and
timing adjustments.
• Values can be entered directly. However, note
that entered values are not checked for appropri-
ateness, and that input of an incorrect value may
result in abnormal operations.

Te s t m o d e
2.List of menu items
2-1. Menu i tems in Normal SE mode

• The following shows the menu items.
• Items indicated against a color background in the table are added to the menu at the time of
Test mode startup.
Items indicated against a red background are data setting menu items used for adjustment.
Menu item Type Description

1. Print Position Adj • This function is used to adjust paper printing positions.
• Positions can be adjusted up to 20.0 mm from the top, bottom,
right, and left margins in 0.5-mm increments.
2. Test Print • This function outputs an image temporarily stored in the main
units memory.
• The number of test print sheets does not affect the number of
pages to be printed set from the PC.
3. Temp Data Retrieve • This function is used to retrieve temporarily stored data and to
set the number of pages to be printed in addition to the base
value.
4. Configuration
4.1 Standard Feed Tray
4.1.1 Paper Size • This function is used to set the size of paper placed in the feed
tray.
• Select auto, standard size paper, or paper size registered for
paper size.
4.1.2 Paper Type • This function is used to set the type of paper placed in the feed
tray.
• (When the setting described in 5.8.14 is Japan mode):
Select from HC ordinary paper, HC matte-coated paper, ordi-
nary paper, post card (IJ), post card, or one of the registered
paper types 1 to 5.
Post card (IJ) and post card are not available for Trays 1 and 2.
• (When the setting described in 5.8.14 is overseas mode):
Select from ordinary paper 1, high quality paper 1, high quality
paper 2, or one of the registered paper types 1 to 5.
4.1.3 Double Feed Check • This function is used to enable or disable multiple feed detec-
tion.
4.2 Feed Tray 1
4.2.1 Paper Size • ->4.1.1
4.2.2 Paper Type • ->4.1.2
4.2.3 Double Feed Check • ->4.1.3
4.2.4 Double Feed Check D • Select the method of detection when [Multiple feed detection]
(Multi-tray paper feed multiple feed) is turned ON in the function setting screen.
• May be set to perform detection from first print (evaluation
based on absolute value of transmitted light) or from the sec-
ond print (evaluation based on relative value (comparison with
previous print)).
• Setting item: From 1st print/From second print (no detection
conducted for first sheet)
• Default: From 2nd print
4.2.5 Dragged Feed Check D • Normally, the multiple feed and dragged multiple feed func-
(Multi-tray paper feed dragged multiple feed) tions are turned ON/OFF in concert, but it is possible to enable
only the dragged multiple feed function. Dragged feed check
can be enabled or disabled when [No multiple feed detection]
is set on the panel of the main unit (printer).
• Setting item: ON/OFF
• Default: OFF
4.3 Feed Tray 2
4.3.1 Paper Size • ->4.1.1
4.3.2 Paper Type • ->4.1.2
4.3.3 Double Feed Check • ->4.1.3
4.3.4 Double Feed Check timing D • ->4.2.4
4.3.5 Dragged Feed Check D • ->4.2.5
4.4 Feed Tray Relay • When two or more feed trays contain paper of the same size
and same type positioned in the same feed direction, this func-
tion automatically switches feed trays for continuous printing.
11 - 3
HC50 00 200 5/1 2 (Rev 3.0 )
4.5 Triple-Tray Source • When the feed tray selection is set to auto, this setting is used
to include or exclude the standard paper feed tray as a paper
source.
4.6 Job Separation • This function inserts separation paper at each break in printing
(between jobs, booklets, or pages).
4.7 Print Density • Allows manual adjustment of print density.
• Print density can be adjusted to one of five levels.
4.8 Paper Ejection
4.8.1 Eject Wing • This is used to set the exit wing position to auto or special.
• The special position is set by service personnel using Test
mode.
4.8.2 Stack Guide • This is used to select the auto exit paper fence adjustment or
fine adjustment from the panel.
4.8.3 Stack Guide Adjust • This is for fine adjustment of the exit paper fence terminal posi-
tions.
4.8.4 Shifting Guide • This allows selection of the exit paper fence terminal positions
when the exit paper open button is pressed.
4.9 Temp Data Clear • This function deletes data remaining in the main unit’s tempo-
rary memory after a print job is completed.
5. Management Information
5.1 Paper Size Entry
5.1.1 Paper Size 1 • This function allows registration of nonstandard paper sizes as
5.1.2 Paper Size 2 Paper Size 1 to Paper Size 5 to allow such paper sizes to be
5.1.3 Paper Size 3 handled in the same way as standard size papers.
5.1.4 Paper Size 4
5.1.5 Paper Size 5
5.2 Paper Type Entry
5.2.1 Paper Type 1 • This function allows registration of selected paper as Paper
5.2.1.1 Registration Type 1 by setting the paper type and paper feed parameters.
5.2.1.2 Paper Type The following settings are made:
5.2.1.3 Paper Feed Control • Paper type indication: ON/OFF
• Paper type (when the setting described in 5.8.14 is Japan
mode):
HC ordinary paper, HC matte-coated paper, ordinary paper,
post card (IJ), post card
• Paper type (When the setting described in 5.8.14 is overseas
mode):
ordinary paper 1, high quality paper 1, high quality paper 2
• Paper feed setting: Standard, thick paper, thin paper, custom
paper, postcard, etc.
5.2.2 Paper Type 2 • -> Same as 5.2.1
5.2.6 HC Ordinary Paper • -> Same as 5.2.1. However, only the Paper Feed Control set-
5.2.7 HC Matte-coated Paper ting is available.
5.2.8 Ordinary Paper
5.2.9 Post Card (IJ)
5.2.10 Post Card
5.3 Separation Paper • Specify the feed tray loaded with separation paper to be
inserted inprint breaks.
5.4 Count Management
5.4.1 Copy Count • This displays the number of copies printed of a single page
regardless of paper size or orientation. These copies are dis-
charged to the exit tray.
• In duplex printing, each side is counted as one copy.
5.4.3 Count Pattern • This displays the number of printed sheets counted based on
preset conditions.
• The print paper size, single-side/duplex printing, and color/
black-and-white are set as counting conditions. (28 different
combinations are possible.)
5.4.4 Maintenance Count • This function displays a maintenance call prompt on the panel
when the counter (adding counter) reaches a preset value (tar-
get value).
• This function can be disabled by setting the target count to 0.

Tes t mode
5.4.4.1 Maintenance Count Entry D This is used to set the number of prints (≈TC) output by the
(Maintenance print count setting) machine before a maintenance call prompt LED lights.
• Setting range: 0 to 9999000 sheets
• Input value: 0 to 9999
• Setting increment: 1 (1000 sheets)
• Default: 0 (0 sheet): No maintenance call indication.
5.4.4.2 Maintenance Count Clear D • This clears the indication (confirmation) of the current count for
(Clear maintenance count (print)) a maintenance call prompt, and resets the counter to zero.
5.4.5 Head Cleaning Counter
5.4.5.1 Start-Up Cleaning C • This displays the number of cleaning operations conducted for
5.4.5.2 Hyper-Cleaning C each head.
5.4.5.3 Normal-Cleaning C • This indicates the number of normal cleaning operations per-
formed.
5.4.5.4 Extra-Cleaning C • This indicates the number of cleaning operations for each
head.
5.4.5.5 Flush-Cleaning C • This indicates the number of cleaning operations for each
head.
5.4.5.6 Head Recovery C • This indicates the number of cleaning operations for each
head.
5.4.6 Tray Counter
5.4.6.1 Standard feed tray C • This displays the counter indication for each feed tray.
5.4.6.2 Feed tray 1 C
5.4.6.3 Feed tray 2 C
5.4.6.4 Duplex C
5.5 Head Maintenance
5.5.1 Start-UP Cleaning
5.5.1.1 K U • Press the Enter key to perform startup cleaning. (Yellow head
5.5.1.2 C U does one each of the start-up cleaning and flush-cleaning.)
5.5.1.3 M U
5.5.1.4 Y U
5.5.1.5 KCMY U
5.5.2 Flush Cleaning
5.5.2.1 K U • Press the Enter key to perform flush cleaning. (Yellow head
5.5.2.2 C U does the flush cleaning in the given times set by SE-Mode
5.5.2.3 M U [5.5.8 Flushing Times].)
5.5.2.4 Y U
5.5.3 Extra Cleaning
5.5.3.1 K U • Press the Enter key to perform extra cleaning.
5.5.3.2 C U
5.5.3.3 M U
5.5.3.4 Y U
5.5.4 Hyper Cleaning
5.5.4.1 K • Press the Enter key to perform hyper cleaning.
5.5.4.2 C
5.5.4.3 M
5.5.4.4 Y
5.5.5 Normal Cleaning • The normal cleaning operation is designed to prevent misfires
5.5.6 Cleaning Cycle in the ink heads. Normal cleaning can be programmed to acti-
vate automatically after a preset number of prints have been
output.
• The heads of all four colors are cleaned at one time in this
mode.
5.5.7 Recovery Cleaning D According to neglect time, automatic cleaning is performed
before a printing start.
The number of cleaning operations depends on the amount of
time between cleanings, as follows:
• 24 hours to 7 days: one normal cleaning operation
7 days to 20 days: three normal cleaning operations
20 days or more: one hyper cleaning operation per color
excluding Yellow ink. Yellow ink does one flush cleaning.
• Setting values: ON/OFF
• Default: OFF
5.5.8 Flushing Times D Sets the number of times the flush cleaning is performed.
• Setting values: 1 to 3 times
• Default: 2 times
11 - 5
HC50 00 200 5/1 2 (Rev 3.0 )
5.6 Config Info Print
5.6.1 System Information • This function outputs the controller (PS7R) settings in list form.
The list can be used as a test print to determine whether the
machine operates normally after settings in the main machine
have been changed.
5.7 Network Config • This function is used to set and register the DHCP, IP address,
subnet mask, and default Flipper gateway.
• After registration, reset power to enter the set values into the
controller.
• Use the PC for settings other than the above network settings.
5.8 Initial Setting
5.8.1 Sleep • This is used to turn the sleep function ON or OFF.
5.8.2 Waiting Time • This function is used to set the sleep activation time. (01 to 99
min)
5.8.3 Beep Sound Key • This is used to turn ON or OFF the buzzer function that pro-
duces a beep when a key input is detected.
5.8.4 Beep Sound -Status • This is used to turn ON or OFF the machine status buzzer
function that produces a beep when a job is generated or an
operation is completed.
5.8.5 Beep Sound Error • This is used to turn the error buzzer ON or OFF.
5.8.6 TempData Retention • This is used to set whether to retain or purge the data for the
last print job held in temporary memory when the job is com-
plete.
5.8.7 Displayed Language • This is used to change the display language.
• Select a display language from seven choices: Japanese, Brit-
ish English, American English, French, German, Italian, and
Spanish. Test mode indications are displayed only in Japanese
or English.
5.8.8 Metric/Inch Switch • This is used to switch the measurement unit (mm/inch) dis-
played on the panel.
• Only mm is shown for Test mode.
5.8.10 Date/Time 2 D This is used to set the Western calendar year, date, and time.
The data is used as a time stamp in the error log and the informa-
tion stored in ink tags.
• Setting values: year, month, date (YY/MM/DD)
• Time (HH:MM)
5.8.11Page Count D This toggles the print counter between additive and subtractive
modes during normal printing operation.
• Setting: Subtracting counter/adding counter
• Default: Adding counter
5.8.12 Fulltank Display D This is used to set a cleaning tank overflow error as a service
error or user error.
• Setting item: Service error/user error
• Default: Service error
5.8.13 Ink Temp Adjust in Sleep Mode D Switches ON/OFF for ink temperature adjustment while in sleep
mode.
• Setting item: ON/OFF
• Default: OFF
5.8.14 Paper Type Switchover D Paper type category can be selected from among the Japan
mode, overseas mode, and a mode combining settings from the
both modes. (The machine should be restarted after changing
the setting.)
If the paper type selected is not available from the specified
paper type category, the default paper type is selected.
• Setting items: Japan mode / overseas mode / all
• Default: Japan mode for Japanese specification model
5.8.16 Serial No.(RISO) C • Confirms the serial No.
5.9 Paper Feed Setting
5.9.1 Standard
5.9.1.1 SPFT Upper Limit D This is used to change the elevator upper limit position setting.
• Setting range: Top/middle/bottom
• Default:
•Standard (U1, U2) -> Middle
•Thick paper (U1, U2) -> Top
•Thin paper (U1, U2) -> Middle
•Custom paper (U1, U2) -> Bottom
•Postcard -> Middle

Te s t m o d e
5.9.1.2 SPFT Postfeed D Adjusting the postfeed amount
• Setting range: -20 to +20 mm
• Setting increment: 1 mm
• Default:
•Standard (U1, U2) -> 0 mm
•Thick paper (U1, U2) -> 0 mm
•Thin paper (U1, U2) -> 0 mm
•Custom paper (U1, U2) -> 0 mm
•Postcard -> 0 mm
5.9.1.3 SPFT Prefeed D Adjusting the feed start timing
• Setting range: 0 to 40 mm
• Default:
•Standard (U1, U2) -> -5 mm
•Thick paper (U1, U2) -> -5 mm
•Postcard -> -5 mm
5.9.1.4 SPFT Assist D Adjusting the amount of assist
• Default:
•Postcard -> 0 mm
5.9.1.5 SPFT Wfeed D Switching multiple feed detection ON/OFF
• Setting: ON (enables multiple feed detection)/OFF (disables
multiple feed detection)
• Default:
•Standard (U1, U2) -> ON
•Thick paper (U1, U2) -> ON
•Thin paper (U1, U2) -> ON
•Custom paper (U1, U2) -> ON
•Postcard -> ON
5.9.1.10 Tray1 Postfeed D Adjusting the postfeed amount. This item appears only if the
standard paper feed tray is mounted on the base.
• Default:
5.9.1.11 Tray1 Assist D Adjusting the amount of assist. This item appears only if the stan-
dard paper feed tray is mounted on the base.
• Setting range: ON/OFF
• Default:
•Standard (U1, U2) -> OFF
•Thick paper (U1, U2) -> OFF
•Thin paper (U1, U2) -> OFF
•Custom paper (U1, U2) -> OFF
5.9.1.20 Tray2 Postfeed D Adjusting the postfeed amount. This item appears only if the
standard paper feed tray is mounted on the base.
• Default:
5.9.1.21 Tray2 Assist D Adjusting the amount of assist. This item appears only if the stan-
dard paper feed tray is mounted on the base.
• Setting range: ON/OFF
• Default:
•Standard (U1, U2) -> OFF
•Thick paper (U1, U2) -> OFF
•Thin paper (U1, U2) -> OFF
•Custom paper (U1, U2) -> OFF
11 - 7
HC50 00 200 5/1 2 (Rev 3.0 )
5.9.1.30 Single Page Gap D Adjusting the gap between paper (value at 7 drops)
• Default:
•Postcard -> 35 mm
5.9.1.31 Duplex Page Gap D Adjusting the gap between paper (value at 7 drops)
• Default:
5.9.1.32 Head Gap D Adjusting the distance between paper and heads
• Setting increment: 0.1 mm
• Default:
•Thick paper (U1, U2) -> 0.2 mm
•Custom paper (U1, U2) -> 1.0 mm
•Postcard -> 0.2 mm
5.9.1.33 BP Speed Rate D Adjusting the speed ratio between registration rollers and belt
• Setting range: -95 to +102%
• Setting increment: 0.1%
• Default:
•Standard (U1, U2) -> 101.0%
•Thick paper (U1, U2) -> 100.2%
•Thin paper (U1, U2) -> 101.0%
•Custom paper (U1, U2) -> 100.2%
•Postcard -> 101.0%
5.9.1.34 Limited Max. Speed D If the print mode for 300-5 drops is selected by the PS7R control-
ler while that for 300-7 has been specified, the 5 drop-image data
received from the PS7R are output at the paper feed speed for 7
drops.
• Default:
•Standard (U1, U2) -> 300-3
•Thick paper (U1, U2) -> 300-3
•Thin paper (U1, U2) -> 300-3
•Custom paper (U1, U2) -> 300-3
•Postcard -> 300-3
5.9.1.40 Wing Offset D Adjusting the wings
• Default:
•Thin paper (U1, U2) -> 0mm
5.9.1.50 Re-feed Postfeed D Amount of re-feed postfeed
• Setting range: -10 to 10 mm
• Default:
•Postcard -> 0 mm

Te s t m o d e
5.9.1.51 Re-feed Assist D Amount of re-feed assist
• Default:
•Postcard -> 0 mm
5.9.1.60 AS Sidefence Offset D Amount of paper guide offset
• Default:
•Thin paper (U1, U2) -> -4 mm
•Postcard -> 8 mm
5.9.1.61 AS Endfence Offset D Amount of paper stopper offset
• Default:
•Postcard -> 0 mm
5.9.1.62 Paper Selection D Display/hide registered paper types (Standard U1, Standard U2,
...Custom U2) as options in [Paper feed setting].
• Setting item: Display/Hide
• Default: Hide
5.9.2 Thick Paper D • Same as 5.9.1.
5.9.3 Thin/Light D • Same as 5.9.1.
5.9.4 Custom D • Same as 5.9.1.
5.9.5 Standard U1 D • Same as 5.9.1.
5.9.6 Thick Paper U1 D • Same as 5.9.1.
5.9.7 Thin/Light U1 D • Same as 5.9.1.
5.9.8 Custom U1 D • Same as 5.9.1.
5.9.9 Standard U2 D • Same as 5.9.1.
5.9.10 Thick Paper U2 D • Same as 5.9.1.
5.9.11 Thin/Light U2 D • Same as 5.9.1.
5.9.12 Custom U2 D • Same as 5.9.1.
5.9.13 Card Stock D • Same as 5.9.1.
5.10 Firmware Revision C • Displays CPU version information.
• PLIP:ORIP PCB
• PLMC:ORMC PCB
• PLPR: HC Control PCB
• PTPL: FL Control PCB
• NOPL
5.11 History
5.11.1 Error Log C • 5.11.1.1 to 64
• Displays a list of errors (Type-S, X) previously generated in
normal mode (64 max.).
• Shows the date, error no., and total count.
5.11.2 Set SW History C • 5.11.2.1 to 10
• Displays set SW errors (Type-Z) that halted operations.
(10 max.)
• Shows the date, error no., and total count.
5.12 System Management
5.12.1 Initialize Unit U • Conducts an HP reset for unit initialization mechanisms. (BP,
wings, maintenance, etc.)
5.12.2 Error Clear D • Normally, when an error is generated, the cause of the error
must be eliminated by conducting the specified error reset pro-
cedure. This setting allows the user to override this require-
ment and reset internal parameters.
5.12.3 Clear User Area D • Clears the data (function/administrator settings, etc.) in the
user area. (Restores default values.)
5.12.4 Clear Test Mode Area D • Restores all settings entered in Test mode to their factory set-
tings.
11 - 9
HC50 00 200 5/1 2 (Rev 3.0 )
5.12.7 Factory Default D • Set the Users area and Test mode area to the default setting.
• Buzzer sounds if the setting is not at default condition.
5.13 System Fitting
5.13.1 System Fitting D • Checks the compatibility of [HC unit (MC PCB)] - [HC Control
PCB] - [Ink] in temporary entry and switches off the [Mainte-
nance call] indication if they are found to be compatible.
5.13.2 Cancel Fitting D • Reset the confirmation of 5.13.1
• Maintenance Call identification lights up if the test mode is acti-
vated while the machine is still tentatively registered.
5.13.3 Machine ID C • Displays the machine type ID sent from the HC Control PCB.
6. Feed Tray Selection
7. Job Clear
8. Check/Setting/Ady
8.1 Drive Check
8.1.1 SPFT Unit
8.1.1.1 Elevator motor U • Activates the elevator ascending/descending operation. Also
displays the ON (light path blocked)/OFF status of the lower
limit sensor and upper limit sensor A, B.
• Pressing the right key raises the elevator in four steps. Press-
ing the left key lowers the elevator all the way to the lowermost
position.
8.1.1.2 Button LED U • Elevator button LED operation check
• If the LED is not lit, pressing the right key turns it ON.
• If the LED is lit, pressing the left key turns it OFF.
8.1.1.3 Servo Action U • Activates the elevator servo.
• This function is disabled when the standard paper feed tray is
empty.
• When the system is not operating, press the right key to acti-
vate the servo. Press the right key once again to halt the oper-
ation.
8.1.2 MTF Feeder Unit
8.1.2.1 FL Transfer motor M • Checks the motor operations.
8.1.2.2 Multi feed tray pickup motor • Pressing the right key activates the operation. Pressing the
8.1.2.3 Feed tray 1 clutch right key once again halts the operation.
8.1.2.4 Feed tray 2 clutch
8.1.2.5 Transfer clutch 1
8.1.2.9 Nip release solenoid 1•2 • Checks the solenoid operation.
8.1.2.10 Nip release solenoid 3•4 • Pressing the right key starts the operation. The operation stops
automatically after one second.
8.1.3 BP Unit
8.1.3.1 Transfer motor U • Activates the blower fans and belt motor.
• The right and left keys are used to adjust the speed.
• Displays speed converted from the belt motor-axis encoder
and belt encoder outputs.
8.1.3.2 Paper feed motor U • Checks main motor operations.
• Displays speed converted from the main motor encoder output.
8.1.3.3 Pickup clutch M • Checks clutch operations.
8.1.3.4 Registration clutch • Pressing the right key activates the drive operation. Pressing
8.1.3.5 Registration brake CL the right key once again halts the operation.
8.1.3.6 Registration roller operation M • Activates the interlock function for the motor and clutch to turn
the registration rollers ON/OFF.
• Motor speed: 300 to 7
• Pressing the right key activates the drive operation. Pressing
the right key once again halts the operation.
8.1.3.7 Registration roller nip U • Activates the interlock function for the motor and clutch to con-
trol the registration roller nip.
• When nip condition and release condition cannot be detected,
both are displayed at all times.
8.1.3.8 Blower fan 1 M • Pressing the right key activates the drive operation. Pressing
8.1.3.9 Blower fan 2 the right key once again halts the operation.
8.1.3.10 Blower fan 3
8.1.3.11 Blower fan 4
8.1.3.12 Gate solenoid
8.1.3.13 Duplex path CL

Te s t m o d e
8.1.3.14 Duplex belt M • Drives the duplex belt.
• Setting display: OFF/600-7/600-6/···/300-3
8.1.3.15 Switchback CL M • Pressing the right key activates the drive operation. Pressing
8.1.3.16 Switchback motor U • When the system is not operating, pressing the left key acti-
vates the vacuum operation. Pressing the right key starts the
discharge operation.
• Pressing the left key while the vacuum operation is underway
halts the process. When the machine is discharging, pressing
the right key halts the operation.
8.1.3.17 Re-feed clutch M • Pressing the right key activates the drive operation. Pressing
8.1.3.18 Re-feed brake the right key once again halts the operation.
8.1.3.19 Re-feed roller U • Activates the interlock function for the motor and clutch to turn
the re-feed roller ON/OFF. The motor speed is 300-7.
• Pressing the right key activates the drive operation. Pressing
8.1.3.20 Exit motor U • Pressing the right key activates the drive operation. Pressing
• Displays the rotation speed.
8.1.3.21 Exit Wing U • When the exit wings are fully closed, pressing the right key
activates the extending operation. If they are fully extended,
pressing the left key activates the folding operation.
• Displays the ON/OFF status of the wing HP sensor.
8.1.3.22 DF Sensor Light Intensity U • Sets the light intensity for multiple feed detection.
• Displays the DA value of the set light intensity.
• Displays the sensor AD value.
8.1.3.23 Cleaning Fan 1 M • Checks the operations of the dust fan (main motor control
PCB).
8.1.3.24 Cleaning Fan 2 M • Checks the operations of the dust fan (MC PCB).
8.1.4 Platen Elevation
8.1.4.1 Elevator clutch M • Elevator clutch (BP elevator clutch)
8.1.4.2 Elevation operation U • When the platen is at the lower limit position, pressing the right
key raises it to the upper limit position through three steps.
• Displays the ON (light path blocked)/OFF status of the lower
limit, vacuum, and upper limit sensors.
• This function is disabled when the ink pan is retracted.
8.1.5 Head maintenance
8.1.5.1 Ink pan U • When the ink pan is at the operating position, pressing the left
key retracts it. Pressing the right key moves it to the operating
position.
• Displays the sensor status.
8.1.5.2 Suction nozzle U • When the suction nozzle is at the home position, pressing the
right key moves it toward the back. Pressing the left key moves
it forward.
• Displays the HP sensor status.
8.1.5.3 Pressure pump C • With the KCMY pressurizing valves open, when the pressure
pump is not operating, pressing the right key activates the
pump. The pump stops automatically after one revolution.
• When the pump is operating, pressing the right key halts the
operation. (Continuous revolution is not possible.)
8.1.5.4 K Pressure valve M • Operations of the reservoir pressurizing valve
8.1.5.5 C Pressure valve • When the valve is closed, pressing the right key opens it.
8.1.5.6 M Pressure valve Pressing the right key once again closes it.
8.1.5.7 Y Pressure valve
8.1.5.8 Suction pump M • When the system is not operating, pressing the right key acti-
vates the drive operation. Pressing the right key once again
halts the operation.
8.1.6 Ink supply
8.1.6.2 K Supply valve M • Operations of the reservoir supplementary valve
8.1.6.3 C Supply valve • Operable only when the ink cover is open.
8.1.6.4 M Supply valve • When the valve is closed, pressing the right key opens it. The
8.1.6.5 Y Supply valve valve closes automatically after 1 sec.
8.1.6.6 KRSV Air valve M • Operations of the reservoir air open valve
8.1.6.7 CRSV Air valve • When the valve is open, pressing the right key closes it. Press-
8.1.6.8 MRSV Air valve ing the right key once again opens it.
8.1.6.9 YRSV Air valve
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HC50 00 200 5/1 2 (Rev 3.0 )
8.1.6.10 KDST Air valve M • Operations of the ID unit air open valve
8.1.6.11 CDST Air valve • When the valve is closed, pressing the right key opens it. The
8.1.6.12 MDST Air valve valve closes automatically after 1 sec.
8.1.6.13 YDST Air valve
8.1.6.14 KCDST Heater M • Operations of the ID unit heater
8.1.6.15 MYDST Heater • When the heater is not operating, pressing the right key acti-
vates it. Pressing the right key once again halts the operation.
• Also displays the temperature.
8.1.6.16 Cooling fan 1 M • When the system is not operating, pressing the right key acti-
8.1.6.17 Cooling fan 2 vates the drive operation. Pressing the right key once again
halts the operation.
8.1.7 Auto fence
8.1.7.1 Paper guide U • The right key moves the fences to their HP positions.
8.1.7.2 Paper stopper • The left key moves the fences to their limit positions.
• To exit, press the Cancel key.
8.1.7.3 AS1 Cycle U • The following operations are performed:
(1) Returns the exit fences to the HP.
(2) Returns the stopper to the HP.
(3) Moves the exit fences to the MIN positions and stops for 1
sec.
(4) Moves the exit fences to the HP.
(5) Moves the stopper to the MIN positions and stops for 1 sec.
(6) Returns the stopper to the HP.
8.1.8 Other
8.1.8.1 Paper counter U • Each press of the right key increments the counter by one.
8.1.8.2 LCD operation U • Pressing the right key turns on all the LCDs at certain intervals.
Pressing the right key once again turns off the LCDs.
8.1.8.3 LED operation U • Pressing the right key turns on all the LEDs at certain intervals.
Pressing the right key once again turns off the LEDs.
8.1.8.4 Buzzer M • Pressing the right key activates the buzzer. Pressing the right
key once again stops the buzzer.
8.2 Sensor monitor
8.2.1 Cover
8.2.1.1 Cover, front right/front left S • Displays the cover open/close status.
8.2.1.2 Cover, switchback/flipper • When open: OPEN, when closed: CLOSE
8.2.1.3 Cover, ink cover/MTPF paper
feed (Jam release safety SW)
8.2.2 Standard paper feed tray
8.2.2.1 Limit SW, upper side/lower side S • SW ON (elevator motor operable)
• SW OFF for interlocked operation.
8.2.2.2 Lower/Upper Limit Sensors 1, 2 S • U-shaped sensors. Displays the status of each sensor.
Paper Feed Lower/Upper-limit Sensors • Light axis blocked: ON
A, B
8.2.2.3 Elevator button • Displays the ON/OFF status of elevator SW.
8.2.2.4 Remaining paper volume, upper S • Displays the status of the tray volume sensors A/B.
side/lower side • Light receiving condition: ON
8.2.2.5 No paper, paper length S • Displays the status of the paper detection sensor and paper
size detection sensor (reflective sensor).
• Light receiving condition (Turns ON when paper is present)
8.2.2.6 Paper width S • Displays the paper width A/D value.
8.2.2.7 Paper size S • Displays the automatically detected paper size.
8.2.2.8 Paper feed lever S • Displays the status of the paper feed pressure sensor (U-
shaped sensor).
• Light axis blocked by thick paper: ON, standard: OFF
8.2.3 Front feeder
8.2.3.1 Feed sensor 1 S • Displays the status of each sensor. Turns ON when paper is
8.2.3.2 Feed sensor2 present.
8.2.3.3 Feed sensor3 • Only feed sensor 3 is a transmission type sensor; it activates
8.2.3.4 Feed sensor4 (ON) when the light path is blocked. Other sensors are reflec-
8.2.3.5 Separation sensor tive, activating (ON) when they receive light.
• Pressing Enter activates buzzer notification mode, and the
buzzer indicates the sensor ON/OFF status with an audible
buzzer signal. (ON: short beep, OFF: long beep)
8.2.3.6 Feed FG sensor S • Displays the sensor status of the FG sensor of the FL feed
motor.
• U-shaped sensor. Turns ON when the light path is blocked.

Te s t m o d e
8.2.3.7 Door safety SW S • Cover switch for the MTPF left cover.
• SW ON (FL transfer motor operable)
• SW OFF for interlocked operation.
8.2.3.8 Feed tray 1Upper limit S • Displays the sensor status.
8.2.3.9 Feed tray 1 paper detection S • Displays the sensor status.
8.2.3.10 Feed tray 1 paper length • Reflection type sensor. Light receiving condition (turns ON
when paper is present)
8.2.3.11 Feed tray 1 paper width C • Displays 8-bit data (raw data) after A/D conversion of the
power width VR and paper width (mm) after correction of paper
width VR.
8.2.3.12 Feed tray 1 remaining paper vol- S • Displays the sensor status.
ume 1 • If the light path is blocked (by the detection plate), the sensor
8.2.3.13 Feed tray 1remaining paper vol- turns ON.
ume 2 • The remaining paper volume is determined by the combination
of 1 and 2.
8.2.3.14 Feed tray 1 set SW S • SW ON (Feed tray 1 is set)
8.2.3.15 Feed tray 2 upper limit • Same as 8.2.3.8 to 8.2.3.14
8.2.3.16 Feed tray 2 paper detection
8.2.3.17 Feed tray 2 paper length
8.2.3.18 Feed tray 2 paper width
8.2.3.19 Feed tray 2 remaining paper vol-
ume 1
8.2.3.20 Feed tray 2 remaining paper vol-
ume 2
8.2.3.21 Feed tray 2 set SW
8.2.3.22 cover SW C • Cover switch for the left front cover (SW on the right side. Jam
release safety SW for MTPF on the left side).
• SW ON (cover is closed)
8.2.4 Paper feed path
8.2.4.1 Registration sensor S • Displays the status of each sensor. Turns ON when paper is
8.2.4.2 Top edge sensor present.
8.2.4.3 Paper emerge detection sensor • The registration sensor and top edge sensor are transmission
8.2.4.4 Exit sensor sensors. They turn ON when the light path is blocked.
8.2.4.5 Flipper sensor • The paper emerge detection sensor is an U-shaped sensor.
They turn ON when the light path is blocked.
8.2.4.6 Duplex belt front sensor
• Other sensors are reflective sensors. They turn ON when they
8.2.4.7 Duplex belt rear sensor
receive light.
8.2.4.8 Switchback sensor • Pressing Enter activates buzzer notification mode, and the
buzzer indicates the sensor ON/OFF status with an audible
buzzer signal. (ON: short beep, OFF: long beep)
8.2.4.9 Pickup clutch S • Checks the status of the connector connection.
8.2.4.10 registration/brake • Connected: ON, Disconnected: OFF
8.2.4.11 Fans 1, 2, 3, 4
8.2.4.12 Gate solenoid
8.2.4.13 Switchback clutch
8.2.4.14 Duplex path
8.2.4.15 Re-feed/brake
8.2.4.16 Cleaning fan 1
8.2.4.17 Cleaning fan 2
8.2.4.18 CCD (Edge) C • Displays the positional data for the paper edge detected by the
CCD. (Position of the CCD elements)
8.2.4.19 CCD (A/D) C • Displays A/D values detected by the CCD.
8.2.5 Exit wing unit
8.2.5.1 Wing home position S • Displays the sensor status.
8.2.5.2 Exit motor encoder • U-shaped sensor. Turns ON when the light path is blocked.
8.2.6 Belt platen
8.2.6.1 Platen position S • Displays the status of the lower limit, vacuum, and upper limit
sensors.
8.2.6.2 Connector connection (elevation S • Checks the status of the connector connection.
clutch) • Connected: ON, Disconnected: OFF
8.2.7 Head maintenance
8.2.7.1 Ink pan, right/left S • Displays the sensor status.
8.2.7.2 Suction nozzle home position • U-shaped sensor. Turns ON when the light path is blocked.
8.2.7.3 Pressure pump home position
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HC50 00 200 5/1 2 (Rev 3.0 )
8.2.7.4 Suction chamber (ink detection) S • Displays the sensor status.
8.2.7.5 Overflow tank sensor • ON: Ink detected, OFF: No ink
8.2.7.6 Waste fluid bottle, top/bottom S • Displays the sensor status.
8.2.7.7 Chamber sensor S • Displays the sensor status.
• ON: Ink detected, OFF: No ink
8.2.7.8 Connector connection (overflow S • Checks the status of the connector connection.
tank) • Connected: ON, Disconnected: OFF
8.2.8 Ink supply
8.2.8.1 Ink bottle S • Checks whether RISO inks are set.
• Simultaneous evaluation of four inks (KCMY).
• ON: Compatible ink set, OFF: No ink or incompatible ink
8.2.8.2 Ink supply passages S • Displays the ink passage sensor status.
8.2.8.3 Reservoir ink S • Displays the reservoir ink sensor status (Hall element)
• Simultaneous evaluation of four inks (KCMY).
8.2.8.4 Distributor ink S • Displays the ID unit ink sensor status. Simultaneous evaluation
of four inks (KCMY).
• ON: Ink detected, OFF: No ink
8.2.8.5 Distributor temperature S • Displays the temperatures of the ID unit.
• Checks conditions for two colors (KC or MY) at a time.
8.2.8.6 Reservoir connection S • Checks the connection conditions of the reservoirs for the four
color inks (KCMY).
8.2.8.7 Distributor connection S • Checks the connection conditions of the ID units for two colors
(KC or MY) at a time.
8.2.8.8 Distributor valve S • Checks the connection conditions of the ID unit air open valves
for the four color inks (KCMY).
8.2.8.9 Remaining ink volume C • Checks the amount of remaining inks set in the machine.
• Displays the amounts of remaining ink in the 1% unit.
• Displayed ink volume: 100% to 0%
8.2.9 Head
8.2.9.1 - 8.2.9.12 Head temperature C • Displays the head temperature for each four blocks.
8.2.9.14 Connector connection (cooling C • Checks the connection conditions of cooling fans 1 and 2.
fan) • Connected: ON, Disconnected: OFF
8.2.10 Auto fence
8.2.10.1 Paper guide HP sensor S • Displays the sensor status.
8.2.10.2 Paper guide limit sensor • Light axis blocked: ON
8.2.10.3 Paper stopper limit sensor
8.2.10.4 Paper stopper HP sensor
8.2.10.5 Paper removing SW S • Displays the switch condition.
• SW pressed: ON
8.2.10.6 Paper detection sensor S • Displays the sensor status. Reflective sensor.
• Turns ON when light is received (paper detected).
•
8.2.11 Others
8.2.11.1 Panel key S • Checks keys. Displays the name of the pressed key.
8.2.11.2 Connector connection (paper S • Checks the connection condition.
counter) • Connected: ON, Disconnected: OFF
8.2.11.3 Connector connection (CN PCB,
left)
8.2.11.4 Option connection S • Checks the connection of options.
• Pressing the right/left key displays the names of the connected
options in sequence.
8.3 Motor speed adjustment
8.3.1 Belt motor speed adjustment U • Counts the shaft encoder clock count at speed of 300-7 for 5
seconds.
• Compares the actual clock count and theoretical count and
stores the ratio as compensating data in NVRAM.
• Compensating data is activated in the belt motor drive speed
during printing.
8.3.2 Paper feed motor initial adjustment D Used to set the main feed motor initial value in the % unit.
• Setting range: 95% to 108%
• Default: 100%
8.4 Paper width sensor adjustment, standard
paper feed tray

Te s t m o d e
8.4.1 Standard paper feed tray D • Automatic adjustment of the paper width sensor
• Set paper of A3 width (297 mm) and A6 width (105 mm), and
register the paper sizes.
8.4.2 Feed tray 1 D • Automatic adjustment of the paper width sensor
8.4.3 Feed tray 2 • Set paper of A3 width (297 mm) and B5 width (182 mm), and
register the paper sizes.
8.5 Image adjustment
8.5.1 Head adjustment
8.5.1.1.11 - 48 Power supply D Used to set the head drive voltage.
• Setting range: 10.00 to 30.00 V
• Setting increment: 0.1 V
• Default: Set at the factory for each head.
8.5.1.2.1-48 Corrective power supply D • Adjust the print density on each print head.
• Setting range: 10.00 to 30.00 V
• Setting increment: 0.1 V
8.5.1.3.1-48 AL type D Used to set the AL type (acoustic length).
• Setting range: 0 to +5
• Setting increment: 1
8.5.1.4.1-4 Horizontal offset D Used to set the horizontal offset for the CMY head with respect to
the K head.
• Setting range: -1500 to +1500
8.5.1.5.1-20 Horizontal overlap D Used to set the horizontal overlap for each head.
• Setting range: 0 to +2000
8.5.1.7.1-48 Vertical position D Used to set the head vertical direction.
• Setting range: -1000 to +1000
8.5.2 Side mask adjustment
8.5.2.1.1-8.5.2.1.8 D Used to adjust the detection position of the CCD sensor for the
Adjusting the CCD position paper side edge detection and the ink ejection position.
• Default:
•K Right -> 0.5, K Left -> 0.5
•C Right -> 0.5, C Left -> 0.5
•M Right -> 0.5, M Left -> 0.5
•Y Right -> 0.5, Y Left -> 0.5
8.5.2.2.1-8.5.2.2.2 D Adjusts the masking amount.
Adjusting the amount of mask • Setting range: 0 to 20.0 mm
• Default: 0.5 mm
8.5.2.3 Side registration offset D Adjusts the central positions of paper and image.
• Setting range: -20.0 to 20.0 mm
• Default: 0.0 mm
8.5.2.4.1 CCD Gain Adjustment (left) D • Adjusts gain of CCD output values.
• Setting range: 0 to 255
• Default: 55
8.5.2.4.2 CCD Gain Adjustment (right) D • Adjusts gain of CCD output values.
• Default: 80
8.5.2.5.1 CCD Offset Adjustment (left) D • Offsets CCD output values.
• Default: 0
8.5.2.5.2 CCD Offset Adjustment (right) D • Offsets CCD output values.
• Default: 0
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HC50 00 200 5/1 2 (Rev 3.0 )
8.5.3 Top edge position adjustment D Used to set the ink ejection start timing after the detection of the
leading edge of the paper by the top edge sensor.
• Default: 0.5 mm
8.5.4 End mask adjustment • Adjusts masking amount of the tail end of the paper
• This menu is to compensate the paper edge detection devia-
tion due to the change in the masking value in the trailing edge
caused by the change in the leading edge printing position.
• Setting range: 0.0 to +10.0 mm
• Default: 0.0 mm
8.5.5 Image length adjustment D Use to set the image length.
• Setting length: 98.0% to 105.0%
• Default: 100%
8.5.6 Adjustment management
8.5.6.1 Adjustment value storage D • For replacement of the NV-RAM. Temporarily stores the data
in the NV-RAM.
8.5.6.2 Adjustment value loading D • For replacement of the NV-RAM. Loads the data back to the
NV-RAM.
8.6 Maintenance System Adjustment •
8.6.2 Vacuum Scanning Start Position D Adjusts the vacuuming start position of the vacuum nozzle.
• Setting range: 6.0 to 16.0 mm
• Default: 11.0 mm
8.6.3 Vacuum Scanning End Position D Adjusts the vacuuming end position of the vacuum nozzle.
• Setting range: 70.0 to 90.0 mm
• Default: 80.0 mm
8.6.5 BP Vacuum Height Adjustment D Adjusts the position (height) of the BP during vacuum operations.
• Setting range: -2.0 to 3.0 mm
• Default: 0.0 mm
8.7 Jam check •
8.7.1 Registration IN jam detection D Change of the jam detection time of the registration sensor (IN)
• Setting item: 0 mm/+5 mm/+10 mm
• Default: 0 mm
8.7.2 Registration OUT jam detection D Change of the jam detection time of the registration sensor (OUT)
• Default: 0 mm
8.7.3 Exit IN jam detection D Change of the jam detection time of the exit sensor (IN)
• Default: 0 mm
8.7.4 Exit OUT jam detection D Change of the jam detection time of the exit sensor (OUT)
• Default: 0 mm
8.8 MTF feeder unit
8.8.1 CL3 OFF delay adjustment D Used to adjust the OFF delay time of transfer clutch 3.
• Setting item: 0 ms, 16 ms, 20 ms, 30 ms, 35 ms, 40 ms
• Default: 30 ms
8.8.2 Multiple feed light intensity setting D • Feed the specified paper, take out the paper, then press the
right key to make the setting.
8.8.3 Light intensity check (plain paper) C • Displays the standard output A/D value (8-bit data) of the multi-
ple feed sensor and the currently set reference light intensity
(D/A value) of the multiple feed sensor for confirmation.
8.8.4 Light intensity check (thick paper) C • Displays the thick paper output A/D value (8-bit data) of the
multiple feed sensor and the currently set reference light inten-
sity (D/A value) of the multiple feed sensor for confirmation.
8.9 Auto exit tray adjustment
8.9.1 Paper guide position correction D Used to set the offset amount of the exit fence HP position for the
auto fence function.
• Setting range: 0 mm to +/– 5.0 mm (+ for extending)
• Default: 0 mm

Te s t m o d e
8.9.2 Paper stopper position correction D Used to set the offset amount of the stopper HP position for the
auto fence function.
• Default: 0 mm
8.9.3 Postcard paper guide position correc- D Used to set the offset amount for moving the exit fences to the
tion postcard position in the auto fence function.
• Default: 0 mm
8.9.4 Postcard paper stopper position cor- D Used to set the offset amount for moving the stopper to the post-
rection card position in the auto fence function.
9. Test Pattern Print
9.1 Print U • Reflects the setting entered in the same hierarchical level, and
conducts print test.
9.2 Tray Selection D • Setting for print test.
9.3 Feed tray Selection
9.4 RES-DROPS
9.5 Simplex/Duplex
9.6 Copy Number
12. Menu no. input
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HC50 00 200 5/1 2 (Rev 3.0 )

Panel messages
CHAPTER 12: Panel messages
CONTENTS
12 - 1
HC50 00 2 005/12 (Rev 3.0 )
Overview of panel messages
1 . O v e r v i e w o f pa n e l
The panel has an LCD display, LEDs, and keys as shown below. When an error is generated, the
LCD and LEDs indicate information related to the generated error.
Consumables information Data LED LCD Wakeup key & LED Power key& LED
(Soft switch)
Warning LED
Enter key Print mode key & LED

Cursor key
Cancel key
Out line diagram Error Menu key
Panel view
2 . B a s i c s t r u c t u r e o f pa n e l
2-1.Power key
The Power key on the panel is used for operation power ON/OFF. When the power is turned OFF by
this switch, the machine enters the standby status. The main power switch is provided separately on
the main unit.
The power supply conditions are described below.
Power supply LED Status

condition
Main power OFF OFF • The main power switch on the main unit is turned OFF.
• In this condition, the Power key on the panel is disabled.
Standby status Orange • The main power switch is turned ON, but the operation power is
turned Off.
• In this condition, pressing the Power key on the panel turns on
the power and sets the machine in the ready status.
Ready status Green • Power turned ON.
• In this condition, pressing the Power key for more than 1 sec-
ond turns the power OFF and sets the machine in the standby
status. However, the power cannot be turned OFF in the follow-
ing cases.
•When there is an unfinished job.
•When a job is being received.

Panel messages
Power supply LED Status
condition
Sleep status Green • Press the Wakeup key to set the machine in the ready status.
• In this condition, pressing the Power key on the panel turns the
power OFF and sets the machine in the standby status.
2-2.Print mode key

• The Print Mode key on the panel is used to turn the print mode ON/OFF. The status is indicated
by the LED.
LED (green) Status

OFF • Print mode OFF
Lit • Print mode ON
Blinking • The print mode is OFF, and the machine is in standby status in the middle of a
job.
• The keys on the panel provide the following functions.

• When the key repeat function is enabled, key repeat (continuous pressing) is activated when a
key is held pressed for 0.7 or more seconds. During key repeat, the display is refreshed every
0.2 seconds.
Name of key Description

Print mode key • Turns the print mode ON/OFF.
Menu key • Turns the print mode OFF, and activates the menu.
Enter key • Enters a setting, etc.
Cancel key • Cancels a setting before it is entered.
Cursor key • Moves the cursor to the next menu item, next function, or next setting
item in the menu screen. (Up/Down keys).
• Moves the cursor to the right/left direction in the numerical input screen.
• Increments or decrements the numerical value in the numerical input
screen.
• Used to adjust the top, bottom, right, and left printing positions.
• Used for fine adjustment of the exit fences and stopper.
Wakeup key • Wakes up the machine from the sleep status.
Power key • Turns the power ON/OFF.
• When the power is turned OFF by this switch, the machine will enter the
standby status. The main power switch is provided separately on the
main unit.
12 - 3
HC50 00 2 005/12 (Rev 3.0 )
3.Error indication by LEDs
3-1.Outline diag ram

• When an error is generated, numbered LEDs in the diagram light to indicate the location of the
error generated. This LED lighting condition provides the following information.
• The color of the LEDs is red.
LED No. Description LED No. Description

1 Paper feed error 11 K ink error
2 Paper transfer error 12 C ink error
3 Exit error 13 M ink error
4 Duplex entry error 14 Y ink error
5 Duplex transfer error 15 Ink set cover error
6 Duplex switchback 16 Waste ink tank error
entry error
7 Duplex switchback 17 Feed tray 1 error
error
8 Duplex re-feed error 18 Feed tray 2 error
9 Main unit right cover 19 Base left cover error
error
10 Main unit left cover 20 Vertical path upper section error
error
21 Option error
3-2.Cons umabl es in formatio n

• The LEDs in this area indicate the remaining volumes of ink and paper.
• When the levels of K, C, M, and Y inks run low, the corresponding ink color LEDs (orange) lights
up.
• When the remaining paper volume in the standard paper feed tray or the feed tray falls to very
low levels, the corresponding LED (orange) lights up.
• When all the set inks are in correct operating condition, the [i-fit] LED (green) lights up.
3-3.Error types
• When an error is generated, the LED (red) corresponding to the type of the generated error
lights up.
Name of LED Description
Ink change This LED lights up when ink cartridges or the waste ink tank need to be replaced.
Setting check This LED lights up when a cover is out of position.
Service call This LED lights up to indicate a service error.
Paper jam This LED lights up to indicate a paper jam.
Maintenance call This LED lights up when a scheduled maintenance call interval is approaching or the
waste ink tank is reaching full capacity.

Panel messages
4.Panel messages
4-1. Overv iew of messag es

(1) Indication of error codes
Each error notification (error code) consists of an error type, categorized according to error reset
method or panel indication method, and the error point (assigned by a number), which indicates
the time or location at which the error was generated. The error point number is a sequential
value assigned to a mechanical unit. For errors that can occur in individual color systems, such
as heads, a parameter (K, C1, MY, etc.) is added after the error point to indicate the error-gener-
ating color.
Examples of error notification: S01-201, X02-123, W02-321-K1
(2) Error type
Error type Description of error
S • Service call
• This error cannot be reset by the user.
P • Option device error
U • Unit error
X • Jam error
• Also includes errors that can be reset by the user to restore normal operating con-
ditions.
Y • Out of consumables (ink)
Z • Setting check (cover open)
• If this error is generated during operations, the machine halts at the next appropri-
ate point in time.
W • Warning: Continuous operations (action) may generate malfunctions. Confirm that
it is safe to continue operations before doing so.
P • Option error
M • Maintenance
(3) Error point
Unit No. Error point Unit
0 0xx System (power supply, H/W, S/W, communication), panel
1 1xx Paper discharge system
2 2xx Belt platen, duplex transfer system
3 3xx(-**) Heads and related parts
4 4xx Multi-tray paper feed
5 5xx Option
* “xx” indicates a sequential value assigned to an internal part of a unit.
12 - 5
HC50 00 2 005/12 (Rev 3.0 )
5 . Ty p e s o f e r r o r s
5-1.Error type
(1) Service call
Type Name Indication Overview/reset method
S01 BP motor lock Service call The main transport system cannot be controlled appropri-
Reset ately.
S02 Elevator motor lock power. The elevator cannot be controlled appropriately.
S03 Belt platen lock Or call a The belt platen elevation mechanism cannot be set prop-
service engineer. erly.
S04 Head maintenance error Head maintenance cannot be controlled appropriately.
Including waste ink tank full condition.
S05 Head thermistor error Head temperature control is malfunctioning.
S06 Ink heating error Ink heating control is malfunctioning.
S07 Ink cooling error Ink cooling control is malfunctioning.
S08 Controller (PS7R) error Communication with the controller (PS7R) cannot be
achieved.
Or an error notification has been received from the con-
troller (PS7R).
S09 Exit option error A service error is generated in the exit option.
S10 Multi-tray paper feed error A service error is generated in the multi-tray paper feed.
S11 Paper feed motor lock The paper feed motor cannot be controlled appropriately.
S12 Exit motor lock The exit motor cannot be controlled appropriately.
S13 Blower fan lock The blower fans cannot be controlled appropriately.
S14 Waste ink tank error The waste ink tank is full.
S15 Ink distributor ink level down
S16 Auto fence error Error exists on the paper receiving tray auto-fence.
S94 Download error (loader) Communication error or data error during downloading.
S95 Download error Communication error or data error during downloading.
S96 PCB or hardware disconnec- The PCB is not connected.
tion
S97 Power supply error There is a problem with the power supply.
S98 Hardware error The hardware cannot be controlled appropriately.
S99 Software error For debugging
<>[ Error resetting method ]
<>Reset power, or execute [Clear error] in Test mode.
<>Some errors (such as PCB disconnection) may not be cleared by executing [Clear error].
<>Even if an S error occurs, it may be possible to continue operations using another unit. Therefore,
certain error types require a specific reset procedure (described in Error Point).
Type Name Indication Description/Reset method

X01 Paper jam in paper feed sec- No paper transport Paper jammed between the first paper feed section and
tion Remove the the second paper feed section.
jammed paper. Jammed paper must be removed from the standard
paper feed tray side.
Open and close the main unit cover, or press the Cancel
key on the control panel.

Panel messages
X02 Paper jam in main paper Jammed paper Paper jammed at the registration rollers or belt platen
transfer section Remove the section. Also covers multiple feeds.
jammed paper. Remove all sheets from the paper transport path except
for the vertical transfer unit, then close the main unit
cover.
(This error is automatically cleared if there is no paper on
the paper transport path when the recovery operation is
activated by opening and closing the main unit cover.)
X03 Paper jam in exit unit Paper jammed near the exit unit outlet section.
Same as X01.
X04 Paper jam in duplex entry Paper jammed in the flipper section.
section Same as X01.
X05 Paper jam in duplex transfer Paper jammed in the duplex transfer section.
section Same as X01.
X06 Paper jam in duplex switch- Paper jammed in the duplex switchback entry section.
back entry section. Same as X01.
X07 Paper jam in switchback sec- Paper jammed in the switchback section.
tion. Same as X01.
X08 Paper jam in re-feed unit Paper jammed in the re-feed unit.
Same as X01.
X09 Paper jam in feed tray 1 No paper transport Paper jammed in feed tray 1
Remove the Open and close feed tray 1.
X10 Paper jam in feed tray 2 jammed paper. Paper jammed in feed tray 2
Open and close feed tray 2.
X11 Paper jam in vertical path Jammed paper Paper jammed in the upper section of the vertical path.
upper section Remove the (This error is cleared if FL feed sensors 1 through 4 are
jammed paper. OFF when the door of the vertical transfer unit is opened
and closed, or the jam release safety SW switches OFF/
ON.)
X12 Paper jam in vertical path Paper jammed in the lower section of the vertical path
lower section Same as X11
X13 Paper jam in vertical path X11 and X12 are generated simultaneously.
upper and lower sections Same as X11
X14 Main unit multiple feed Multiple feed Multiple paper feed occurred.
X15 Multi-tray paper feedmultiple Remove the Open and close the door of the vertical transfer unit, or
feed jammed paper. open and close the left front cover.
(Turns the jam release cover safety SW OFF/ON.)
(2) Consumables error
Y01 Ink cartridge change No ink No ink
Change Remove the applicable ink cartridge.
ink cartridge(s).
Y02 Waste ink tank change Waste ink tank full. The waste ink tank is full.
Replace (The default message setting for the service error indica-
ink cartridge(s). tion is [Service error: S14]. The setting can be changed in
Test mode.)
Remove the waste ink tank.
(This error is cleared when the tank full sensor is acti-
vated or deactivated (i.e., turned ON/OFF).)
(3) Setting check error
Z01 Ink cartridge not set No ink cartridge Ink cartridge(s) not set
Set ink cartridge(s). Set ink cartridge(s).
Z02 Incompatible ink color Ink cartridge error Ink cartridges of the incorrect color are set.
Check ink cartridges. Remove the ink cartridges.
Z03 Incompatible ink cartridge An incorrect ink cartridge is set.
Remove the ink cartridges.
Z04 Ink cover not set The cover is open. The ink bottle cover is open.
Close Close the ink bottle cover.
Z05 Front cover not set the cover. The front cover (left/right) is open.
(left/right) Close the front cover (left/right).
Z06 Transfer cover (left) not set The transfer cover (left) is open.
Close the transfer cover (left).
Z07 Transfer cover (right) not set The transfer cover (right) is open.
Close the transfer cover (right).
Z08 Vertical transfer unit door not The left door of the MTPF is open.
set Close the left door of the MTPF.
12 - 7
HC50 00 2 005/12 (Rev 3.0 )
Z09 Feed tray 1 not set Feed tray open Feed tray 1 is open.
Check feed tray. Close the applicable feed tray.
This error is ignored while paper fed from the standard
paper feed tray is being printed.
or during head maintenance.
Z10 Feed tray 2 not set Feed tray 2 is open.
Close the applicable feed tray.
This error is ignored while paper fed from the standard
paper feed tray is being printed.
or during head maintenance.
Z11 Standard paper feed tray Feed tray error The safety SW for the standard paper feed tray is
check Check pressed.
paper feed tray. Or both the Upper and Lower Limit Sensors are activated
(too much paper on the tray).
Deactivate the safety SW for the standard paper feed
tray.
Remove the overloaded paper from the standard paper
feed tray to release the Upper/Lower-Limit Sensor.
Z12 Waste ink tank No waste ink tank The waste ink tank is not set.
not set Check ink tank. Set the waste ink tank.
Z13 Ink passage opening failure The cover is open. The ink passage opening operation failed.
Close the cover. Open the ink bottle cover.
Z14 Jam release SW check The cover is open. The jam release cover safety SW is OFF.
Close the cover. Set the jam release cover safety SW to ON.
(Normally, the SW is released when the left front cover is
closed.)
(4) Warning
W01 Paper change No paper No paper (When any tray is empty)
Set paper. Set paper in one of the feed trays.
W02 No paper (Standard paper No paper The standard paper feed tray is empty when paper feed
feed tray) Set the appropriate is selected.
paper. Press the Cancel key on the panel.
Or load the applicable feed tray with paper.
Or select another feed tray (Menu 6).
Or clear the print job (Menu 7).
W03 No paper (Feed tray 1) The feed tray 1 is empty when paper feed is selected.
Same as W02
W04 No paper (Feed tray 2) The feed tray 2 is empty when paper feed is selected.
Same as W02
W05 No paper (Auto) The auto feed tray selected is empty.
Same as W02
W06 No separation sheets No paper is available when the sorting function is
inserted between print jobs selected.
Press the Cancel key on the panel.
Or load paper on the Sorting Tray.
Or disable the sorting function.
Or switch to another tray from the Sorting Tray (Menu
5.3).
Or clear the print job (Menu 7).
W07 Auto fence operation not pos- Check The auto fence function is invalid.
sible paper receiving tray. Press the Cancel key on the panel.
Or disable the auto fence function (Menu 4.8.2).
W08 Controller HDD full Controller/HDD is full. The HDD of the controller is full.
Delete unnecessary data from the HDD.
Or the error is automatically cleared when free space is
available on the HDD.
*The error appears while processing a new job, but when
the error occurs, the processing job is automatically
deleted, so the error message also resets automatically.
W99 Head maintenance Perform the cleaning. Confirming head maintenance execution
Perform head maintenance (normal).

Panel messages
(5) Maintenance
M01 Maintenance call The print count has reached the scheduled maintenance
value.
Run Test mode [Clear error] (5.12.2).
Or set the scheduled maintenance value to [0].
Or clear the scheduled maintenance value.
M02 Waste ink tank The waste ink tank The waste ink tank needs to be replaced soon.
Near full needs to be replaced. Replace the waste ink tank.
(This error is cleared when the absence of a waste ink
tank is detected.)
Or
the waste ink tank is full (automatic clear).
M03 Operation in temporary regis- The machine is currently operating under temporary reg-
tration status istration.
Run Test mode [Conformity check] (5.13.1) while tempo-
rary registration status is in effect.
It will clear automatically when the temporary registration
period expires.
M04 Incorrect ink version number Need to replace the ink No discharging parameter on the mounted ink cartridge.
information. Upgrade the machine program version.
5-2. Exp lanation o f pa nel m essages
Point Type Error detection condition

001 S96 Power supply remote signal not connected
The control signal cable for the ON/OFF control of the 24/38-VDC output is disconnected. The sig-
nal wire grounded inside the power supply unit has been pulled up by the IP PCB to detect the
level.
003 S97 38-VDC power supply voltage error
A voltage drop is detected when a voltage drop is sensed by the IP PCB based on the signal
resulting from dividing the 38-VDC resistance inside the power supply unit. The detection level is
approximately 18 VDC.
Voltage polling is conducted at 100-ms intervals by the IP-CPU. An error is detected when a volt-
age drop is sensed 10 times in succession (approx. 1 sec). No detection is performed when the
interlock SW is open.
004 S97 24-VDC power supply voltage error
A voltage drop is detected when a voltage drop is sensed by the IP PCB based on the signal
resulting from dividing the 24-VDC resistance inside the power supply unit. The detection level is
approximately 11 VDC.
age drop is sensed 10 times in succession (approx. 1 sec). No detection is performed when the
interlock SW is open.
006 S97 3.3-VDC power supply voltage error
A voltage drop is detected when a voltage drop is sensed in the 3.3-VDC power supply on the MIP
side of the IP PCB.
age drop is sensed 10 times in succession (approx. 1 sec).
007 S97 1.8-VDC power supply voltage error
A voltage drop is detected when a voltage drop is sensed in the 1.8-VDC power supply on the MIP
side of the IP PCB.
age drop is sensed 10 times in succession (approx. 1 sec).
008 S96 Control panel not connected
The absence of the control panel unit to be connected to the MC PCB is detected. Since this con-
figuration lacks this panel, this error indication will not be issued under normal operating circum-
stances.
009 S96 Print counter not connected
The absence of a print counter is detected.
011 S96 CIS PCB not connected
The connection of the CIS PCB cannot be confirmed.
012 S98 IP PCB not connected (communication error)
The IP PCB is not connected.
Since the MC PCB receives its power from the IP PCB, this error indication will not be issued
under normal operating circumstances.
013 S96 K head driver PCB not connected
The connection of the K color head driver PCB cannot be confirmed with the connection detection
signal.
12 - 9
HC50 00 2 005/12 (Rev 3.0 )
014 S96 C head driver PCB not connected
The connection of the C color head driver PCB cannot be confirmed with the connection detection
signal.
015 S96 M head driver PCB not connected
The connection of the M color head driver PCB cannot be confirmed with the connection detection
signal.
016 S96 Y head driver PCB not connected
The connection of the Y color head driver PCB cannot be confirmed with the connection detection
signal.
017 S98 Control panel LCD error
An error was detected in the panel LCD drive chip. Since the LCD driver will not operate when this
error occurs, this error indication will not be issued under normal operating circumstances.
018 S98 K head driver PCB error
Head Driver PCB error is indicated when:
A head driver PCB configuration error has occurred.
A failure by the MIP to respond to a data request from the head driver PCB has been detected.
A communication error between the head driver PCB and IP has been detected.
A 38-V voltage error in the head driver PCB has been detected.
019 S98 C head driver PCB error
Same as when detecting a K head driver PCB error.
020 S98 M head driver PCB error
021 S98 Y head driver PCB error
022 S98 MC PCB FPGA program error
Improper operation of the FPGA program on the MC PCB was detected.
023 S98 IP PCB MIP program error.
MIP configuration on the main PCB failed.
024 S98 IP PCB SPLD program error
SPLD configuration on the main PCB failed.
025 S99 For debugging:
A DC startup report does not arrive from the IP-CPU within the specified time.
The IP-CPU does not respond to the sensor monitor demand from the MC-CPU.
The IP-CPU does not respond to the SQR from the MC-CPU.
028 S96 ORCNL PCB on machine left side not connected
The connection of the ORCNL PCB on the machine left side cannot be confirmed.
029 S96 HC Control PCB timeout
The Busy signal on the HC control PCB will not be deactivated upon the start of communication
from the MC PCB.
030 M01 Maintenance call
Maintenance count reached the maximum at machine ON, all-reset, or at end of print job.
* The maintenance count is set by the Test Mode.
031 S99 Multi-tray paper feed communication error 1
Multi-tray paper feed power line error
032 S99 Multi-tray paper feed timeout
The machine status command transmitted from the paper feed device on the base was outside
the specified range (phase error).
Or the [Preparation complete] status command was not received within the specified interval after
receiving the [Preparing] status command.
The machine status command was not received from the paper feed device on the base within the
specified interval (when the papaer feed device on the base does not respond).
Base paper feed initialization information completion command was not received within the speci-
fied time of 1 second after the base paper feed initialization command was issued.
Status information could not be transmitted during communications with the auto fence function
within the specified interval.
036 S99 Auto fence communication error
A Test mode status command was not received before the elapse of the specified interval after the
transmission of the Test mode execution command.
Multi-tray paper feed communication transmission error
Multi-tray paper feed communication reception break error
Multi-tray paper feed communication transmission buffer error

Panel messages
040 S98 R/W PCB failure 1
Initial communication with the R/W PCB failed.
Run signal timeout
Connection signal timeout (The PCB is not connected.)
043 S96 HC Control PCB not connected
The connection of the HC Control PCB cannot be confirmed.
(The HC Control PCB READY signal cannot be confirmed when the IP PCB is powered on.)
044 S99 HC Control PCB communication error (timeout error)
A command from the HC Control PCB was not received during the HC Control-MC communica-
tion within the specified interval.
045 S95 Download error (HC Control PCB detection)
An error was detected on the HC Control PCB side during a download.
046 S95 Download error (IP PCB detection)
An error was detected on the IP PCB side during a download.
047 S95 Download error (MC PCB detection)
An error was detected on the MC PCB side during a download.
048 S99 FRAM checksum error
FRAM checksum error of the HC Control PCB
049 S99 FRAM read verify error
The data does not match data read from the FRAM of the HC Control PCB.
050 S99 FRAM write verify error
The data does not match data written to the FRAM of the HC Control PCB.
051 M03 Operation in temporary registration status
The main unit is currently operating under temporary registration.
052 S98 Date/time setting error
The date/time is not set correctly.
The clock is set with a date predating the PLIP firmware release date.
Or
the clock is set with a date postdating the year 2030.
053 S99 FRAM access error
The FRAM of the HC Control PCB could not be accessed normally.
054 S95 Error in the downloaded data.
Error in the downloading data received.
055 S99 Machine information software error.
Error detected by the HC Control PCB while processing the machine type data.
056 S99 Machine software error (debug error)
057 S99 Communication error between IP-MC PCBs.
Error between IP-MC PCBs during communication.
058 S98 Error on NVRAM.
Error with NVRAM on the machine.
100 S12 Exit motor encoder error
The encoder frequency input from the exit motor unit deviates from the theoretical value.
101 S98 Multiple feed sensor error
A change in light intensity does not change the amount of light received at power ON
or during initialization to reset a multiple feed error.
* This error can be cleared by the panel setting [Multiple feed detection OFF].
102 S12 Wing motor timeout
The wings do not reach the HP when they are operated for a period of time corresponding to the
distance of travel.
103 S12 Wing motor timeout
The wing HP sensor does not detect the movement of the wings from the HP when they are oper-
ated for the specified interval.
104 S02 Elevator motor timeout
The upper limit sensor fails to activate when the elevator rising operation is activated within the
specified interval.
105 X14 Standard paper feed tray multiple feed
A multiple feed was detected during transport of paper from the standard paper feed tray.
106 X01 Standard paper feed tray feed failure (no paper transport)
The registration sensor fails to activate when the specified number of clock inputs is issued from
the belt encoder after paper transport from the standard paper feed tray begins.
107 X03 Exit sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the exit sensor (sensor detecting the presence
of paper) within the specified interval based on the belt encoder pulse count.
108 X02 Jammed paper at registration sensor section when the cover is closed
The registration sensor detects paper when the cover is closed or during the interval in which the
paper transport roller idling is controlled when the cover is closed.
12 - 11
HC50 00 2 005/12 (Rev 3.0 )
109 X03 Jammed paper at exit sensor section when the cover is closed
The exit sensor detects paper when the cover is closed or during the interval in which the paper
transport roller idling is controlled when the cover is closed.
110 W02 No paper in standard paper feed tray
The standard paper feed tray is empty when it is selected as the feed tray.
111 Z11 Standard paper feed tray elevator upper limit SW detection
The upper limit SW for the standard paper feed tray is turned ON.
112 Z11 Standard paper feed tray overfilled
The upper limit sensor and lower limit sensor are turned ON simultaneously for more than 1 sec-
ond at power ON or during a standard paper feed tray moving operation.
113 S96 Pickup clutch not connected
The connection of the pickup clutch cannot be confirmed.
114 S96 Registration clutch not connected
The connection of the registration clutch cannot be confirmed.
115 S96 Registration brake not connected
The connection of the registration brake cannot be confirmed.
116 W01 No paper
All feed trays are empty.
117 W05 No paper (auto)
None of the trays contain the required type of paper when auto feed tray is selected.
118 W06 No separation sheets inserted between print jobs
The separation paper feed tray has run out of paper during a sorting operation.
Or the separation paper feed tray is empty at the beginning of a sorted printing operation.
119 S02 Elevator motor timeout
The lower limit sensor fails to activate during a standard paper feed tray lowering operation within
the specified interval.
120 Z11 Standard paper feed tray elevator lower limit SW detection
The lower limit SW for the standard paper feed tray is turned ON.
121 S96 Dust fan 1 not connected
Connection of dust fan 1 cannot be confirmed.
122 S96 Dust fan 2 not connected
Connection of dust fan 2 cannot be confirmed.
200 S03 Transfer belt motor timeout
The motor shaft encoder of the transfer belt motor does not attain the specified pulse count within
the specified time.
The required movement does not complete even when the transfer belt motor operates for the
specified interval.
201 S03 Transfer belt unit sensor error
The three sensors that determine the position of the belt platen produced an abnormal detection
result.
202 S01 Transfer belt motor error
An alarm signal from the DC servo motor was detected (detection of overcurrent during opera-
tions).
203 S01 Transfer belt motion speed error
The clock frequency of the belt motor shaft encoder falls outside the specified range.
204 S01 Belt encoder error
The frequency input from the belt encoder is below the specified value.
205 S96 Blower fan 1 disconnected/not connected
The connector for blower fan 1 is disconnected, or there is a break in the winding.
209 X07 Duplex re-feed unit failure
the belt encoder after paper is re-fed for duplex printing.
210 X02 Registration sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the registration sensor within the specified
interval based on the belt encoder pulse count.
211 X02 Top edge sensor paper leading edge arrival delay
The leading edge of the paper sheet does not reach the top edge sensor (sensor does not detect
the presence of paper) within the specified interval based on the belt encoder pulse count.
212 X02 Top edge sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the top edge sensor (sensor detecting the
presence of paper) within the specified interval based on the belt encoder pulse count.

Panel messages
213 X02 Exit sensor paper leading edge arrival delay
The leading edge of the paper sheet does not reach the exit sensor (sensor does not detect the
214 X04 Flipper sensor paper leading edge arrival delay
The leading edge of the paper sheet does not reach the flipper sensor (sensor does not detect the
215 X04 Flipper sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the flipper sensor (sensor detecting the pres-
ence of paper) within the specified interval based on the belt encoder pulse count.
216 X04 Flipper sensor unknown paper detection
The flipper sensor detects the presence of paper within the specified interval based on the belt
encoder pulse count even though paper has been discharged to the exit tray.
217 X04 Duplex belt front sensor paper leading edge arrival delay
The leading edge of the paper sheet does not reach the duplex belt front sensor (sensor does not
detect the presence of paper) within the specified interval based on the belt encoder pulse count.
218 X04 Duplex belt front sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the duplex belt front sensor (sensor detecting
219 X05 Duplex belt rear sensor paper leading edge arrival delay
The leading edge of the paper sheet does not reach the duplex belt rear sensor (sensor does not
220 X05 Duplex belt rear sensor paper end exiting delay
The trailing edge of the paper sheet does not pass the duplex belt rear sensor (sensor detecting
221 X05 Switchback sensor paper leading edge arrival delay (in paper vacuum positioning operation)
The leading edge of the paper sheet does not reach the switchback sensor (sensor does not
222 X06 Switchback sensor paper end exiting delay (in paper vacuum positioning operation)
The trailing edge of the paper sheet does not pass the switchback sensor (sensor detecting the
223 X02 Paper lift detection
The paper emerge detection sensor at the transfer belt entrance section detected paper during
printing.
224 X02 Jammed paper at top edge sensor section when the cover is closed
The top edge sensor detects the presence of paper when the cover is closed or during the interval
in which the paper transport roller idling is controlled when the cover is closed.
225 X04 Jammed paper at flipper sensor section when the cover is closed
The flipper sensor detects paper when the cover is closed or during the interval in which the paper
transport roller idling is controlled when the cover is closed.
226 X04 Jammed paper at duplex belt front sensor section when the cover is closed
The duplex belt front sensor detects paper when the cover is closed or during the interval in which
the paper transport roller idling is controlled when the cover is closed.
227 X05 Jammed paper at duplex belt rear sensor section when the cover is closed
The duplex belt rear sensor detects paper when the cover is closed or during the interval in which
the paper transport roller idling is controlled when the cover is closed.
228 X06 Jammed paper at switchback sensor section when the cover is closed
The switchback sensor detects paper when the cover is closed or during the interval in which the
paper transport roller idling is controlled when the cover is closed.
229 Z07 Flipper cover not set
The flipper cover is not set.
230 Z06 Switchback unit not set
The switchback unit is not set.
231 S03 Belt platen operation error
The upper limit position sensor fails to activate when the belt platen rises.
232 S96 Belt platen elevator clutch not connected
The connection of the belt platen elevator clutch cannot be confirmed.
233 S96 Gate solenoid not connected
The connection of the gate solenoid cannot be confirmed.
234 S96 Duplex transport not connected
The connection of the duplex clutch cannot be confirmed.
235 S96 Re-feed pickup clutch not connected
The connection of the re-feed pickup clutch cannot be confirmed.
236 S96 Re-feed brake not connected
The connection of the re-feed brake cannot be confirmed.
237 Z05 Left front cover not set
The left front cover is detected as not set.
238 Z05 Right front cover not set
The right front cover is detected as not set.
12 - 13
HC50 00 2 005/12 (Rev 3.0 )
239 S96 Switchback clutch not connected
The connection of the switchback clutch cannot be confirmed.
The upper limit position sensor fails to deactivate when the belt platen lowers.
The lower limit position sensor fails to activate when the belt platen lowers.
The lower limit position sensor fails to deactivate when the belt platen rises.
The vacuum positioning sensor fails to activate when the belt platen operates.
The vacuum positioning sensor fails to deactivate when the belt platen operates.
245 S98 Error in Image Adjustment
Paper size used in Image Adjustment is out of the range.
Or the scanned data by the CCD is wrong (out of the range).
300 S04 Ink pan motor timeout
The right or left sensor fails to activate within the specified interval.
301 S04 Ink pan sensor error
The right and left sensors activate at the same time.
302 S04 Cleaning motor timeout
The detection plate does not reach the suction nozzle HP sensor even when the motor operates
for the specified interval to move the cleaning motor to the retraction position on the front side.
Or the suction nozzle HP sensor fails to deactivate when it moves from the HP.
303 S04 Suction chamber full
The suction chamber sensor is turned ON.
304 S96 Suction chamber sensor not connected
305 S04 Suction pump rotation speed error
The rotation speed of the suction pump falls outside the specified range (checked by the encoder
clock frequency for the specified time).
307 S04 Overflow tank full
Ink is detected by the overflow sensor.
308 S96 Overflow tank not connected
The connection of the overflow sensor cannot be confirmed.
309 S96 Cooling fan 1 not connected
310 S96 Cooling fan 2 not connected
311 S05 Disconnection in head thermistor
The head temperature could not be measured correctly.
When the reading of the thermistor is -86.9 °C
* Head identification information (K1 - Y6) is added after the error point.
312 S05 Head abnormally hot
The head temperature exceeded 80 °C.
When the reading of the thermistor is 80.0 °C
313 S05 Head cooling timeout
The temperature remained above 45 °C for 10 minutes.
When the monitored head temperature remains 45 °C or more for 10 minutes
314 S06 Ink heating timeout
When the temperature of ink in the distributor meets the following conditions after being heated for
a set time:
1) & either 2), 3) 4), 5), 6) or 7)
1) The temperature is less than 15 °C.
2) It takes more than 360 seconds to raise the temperature by 1 °C after the heater has been
powered on.
powered on.
powered on.
powered on.
6) It takes more than 1,320 seconds to raise the temperature by 13 °C after the heater has been
powered on.
7) A temperature of less than 15 °C holds for more than 1,800 seconds.
* Head identification information (K, C, M, Y) is added after the error point.
315 W99 ID unit low liquid level
Low liquid level is detected in the ID unit of each color ink.
* Ink identification information (K, C, M, Y) is added after the error point.
316 S96 Reservoir not connected

Panel messages
317 S96 ID unit air open valve not connected
318 S96 Distributor unit not connected
* Unit identification information (KC, MY) is added after the error point.
319 S07 Ink cooling timeout
The temperature of ink being distributed remains 40 °C for five minutes.
320 S98 Head voltage error
321 S04 Pressure pump motor timeout
The logic of the pressure pump sensor (detection at motor 180-degree intervals) does not change
even when the pressure pump motor is driven for a certain time period.
322 S96 Waste ink tank not installed
(Z12) The waste ink tank is not installed.
323 S14 Water ink tank full
(Y02) The waste ink tank is detected as full.
324 M02 Waste ink tank near-full
The waste ink tank is almost full.
325 Z04 Ink bottle cover not set
The ink bottle cover is detected as not set.
326 Z13 Ink passage opening failure
The ink open sensor fails to activate when the ink fuse solenoid activates.
The ink open sensor fails to activate after the ink fuse solenoid activates even after a full one sec-
ond elapsed. After a retry, the ink open sensor fails to activate even after a full one second
elapsed.
327 Y01 Ink cartridge change 1
No ink has been detected during printing or maintenance operation.
Ink sensor of the main unit reservoir fails to activate within the specified interval.
No ink has been detected at power ON or when the tag was read after cartridge replacement.
330 Z01 Ink cartridge not set
No ink cartridge detected.
331 Z02 Incompatible ink color
Wrong ink color detected.
332 Z03 Incompatible ink cartridge
333 Z03 Ink tag communication error on R/W PCB side (ink check)
334 Z03 Ink tag communication error on HC Control PCB side (ink check)
335 Z03 Ink tag communication error, other 1 (ink check)
336 Z01 Ink tag communication error on R/W PCB side (no tag)
337 Z01 Ink tag communication error on HC Control PCB side (no tag)
338 Z01 Ink tag communication error, other 1 (no tag)
340 S99 Ink tag software error
(For debugging)
341 Z13 Ink open sensor error
The ink open sensor deactivates (passage closed) in standby or while printing.
343 M04 Incorrect ink version
No discharging parameter on the mounted ink cartridge.
344 S04 Cleaning motor timeout 2
HP sensor does not go ON even after the motor rotates for the specific time period to move the
cleaning motor to the front retracting position.
345 S04 Error on the Cleaning Motor
When the cleaning motor rotated, the pulse count was below the parameter after completion of
moving.
12 - 15
HC50 00 2 005/12 (Rev 3.0 )
346 S04 Cleaning motor timeout 3
HP sensor does not go OFF even after the motor rotates for the specific time period to move the
cleaning motor to the rear.
400 S10 FL transfer motor lock (Detailed No. 1: timeout)
There was no input interrupt from the FL transfer motor FG sensor during FL transfer motor oper-
ation, even after the specified time elapsed.
402 S10 Feed tray 1 elevator motor lock (Detailed No. 1: timeout)
The FL feed tray 1 upper limit sensor fails to activate after the FL feed tray 1 elevator motor turns
ON, even after the specified time elapses.
* This error can be cleared by opening feed tray 1.
403 S10 Feed tray 1 elevator motor lock (Detailed No. 2: overcurrent)
An overcurrent was detected in the FL feed tray 1 elevator motor.
404 S10 Feed tray 2 elevator motor lock (Detailed No. 1: timeout)
The FL feed tray 2 upper limit sensor fails to activate after the FL feed tray 2 elevator motor turns
ON even after the specified time elapses.
405 S10 Feed tray 2 elevator motor lock (Detailed No. 2: overcurrent)
Overcurrent was detected in the FL feed tray 2 elevator motor.
406 S10 Feed tray 1 paper width adjustment parameter error
The correction value for the feed tray 1 paper width VR falls outside the specified range.
* This error can be cleared by opening the feed tray or opening the cover of the vertical transfer
unit.
407 S10 Feed tray 2 paper width adjustment parameter error
The correction value for the feed tray 2 paper width VR falls outside the specified range.
unit.
408 S10 Multi-tray paper feed multiple feed sensor light emitting intensity error
The multiple feed sensor light emitting intensity falls outside the specified range.
unit.
409 S10 Multi-tray paper feed EEPROM error
Data could not be written correctly to the EEPROM.
Or an EEPROM checksum error occurred.
unit.
410 Z14 Jam release SW check
The jam release cover safety SW is OFF.
* Since the jam release safety SW is shared with the main unit left front cover, this error is seldom
displayed.
411 Z08 Vertical transfer unit door not set
The door of the FL vertical transfer unit is open.
412 X15 Feed tray 1 multiple feed (transmission light intensity detection)
A multiple feed occurred during paper transport.
413 X15 Feed tray 1 multiple feed (detection of multiple sheet feed involving dragged trailing sheet(s))
Multiple sheet feed involving dragged trailing sheet(s) occurred during paper transport.
414 X11 Feed tray 1 paper feed failure
the belt encoder after paper transport from feed tray 1 begins.
415 X11 Feed tray 2 paper feed failure
the belt encoder after paper transport from feed tray 2 begins.
416 X12 Multi-tray paper feed jam (Detailed No. 1: S1)
FL transfer sensor 2 failed to activate when the FL transfer motor FG sensor attained the specified
pulse count after FL feed sensor 1 activated during a paper feed operation. (FL feed sensor 1
remained activated.)
Or
FL feed sensor 1 remained activated at power ON or in standby mode.
pulse count after FL feed sensor 2 activated during a paper feed operation. (FL feed sensors 1
and 2 remained activated.)
Or
FL feed sensors 1 and 2 remained activated at power ON or in standby mode.

Panel messages
pulse count after FL feed sensor 3 turned ON during a paper feed operation. (FL feed sensors 1,
2, and 3 remained activated.)
Or
FL feed sensors 1, 2, and 3 remained activated at power ON or in standby mode.
The registration sensor failed to activate when the FL transfer motor FG sensor attained the spec-
ified pulse count after FL feed sensor 4 activated during a paper feed operation. (FL feed sensors
1 through 4 remained activated.)
Or
FL feed sensors 1 through 4 remained activated at power ON or in standby mode.
420 X13 Multi-tray paper feed jam (Detailed No. 5: S1234R)
FL feed sensors 1 through 4 and the registration sensor remained activated in standby mode.
remained OFF, and FL feed sensor 2 remained activated.)
Or
remained OFF, and FL feed sensors 2 and 3 remained activated.)
Or
ified pulse count after FL feed sensor 4 activated during a paper feed operation. (FL feed sensor 1
remained OFF, and FL feed sensors 2 through 4 remained activated.)
Or
FL feed sensors 2 through 4 remained activated at power ON or in standby mode.
Feed sensors 2 through 4, and the registration sensor remained activated at power ON or in
standby mode.
pulse count after FL feed sensor 3 activated during a paper feed operation. (FL feed sensors 1
and 2 remained OFF, and FL feed sensor 3 remained activated.)
Or
1 and 2 remained OFF, and FL feed sensors 3 and 4 remained activated.)
Or
Feed sensors 3 and 4, and the registration sensor remained activated at power ON or in standby
mode.
1 through 3 remained OFF, and FL feed sensor 4 remained activated.)
Or
Feed sensor 4 and the registration sensor remained activated at power ON or in standby mode.
430 X11 Feed tray 1 separation error
The FL multi-tray pickup sensor activated at the feed tray 1 paper feed timing or on receiving a
feed tray setting command.
431 X09 Feed tray 1 no paper transport
FL feed sensor 3 did not turn on when FL feed tray 1 pickup clutch turned ON and the FL transfer
motor FG sensor attained the specified pulse count while paper was being fed from feed tray 1.
432 X10 Feed tray 2 no paper transport
FL feed sensor 1 failed to activate when FL feed tray 2 pickup clutch turned ON and the FL trans-
fer motor FG sensor attained the specified pulse count while paper was being fed from feed tray 2.
433 W03 Feed tray 1 no paper
Although selected as the current feed tray, feed tray 1 is currently empty.
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HC50 00 2 005/12 (Rev 3.0 )
434 W04 Feed tray 2 no paper
Although selected as the current feed tray, feed tray 2 is currently empty.
435 Z09 Feed tray 1 is open.
The feed tray 1 set SW is OFF (detection of feed tray open).
436 Z10 Feed tray 2 is open.
The feed tray 2 set SW is OFF (detection of feed tray open).
437 X15 Feed tray 2 multiple feed (transmission light intensity detection)
A multiple feed occurred during paper transport.
438 X15 Feed tray 2 multiple feed error (detection of multiple sheet feed involving dragged trailing sheet(s))
Multiple sheet feed involving dragged trailing sheet(s) occurred during paper transport.
439 X15 Feed tray 1 multiple feed (detection of multiple sheet feed involving dragged trailing sheet(s) 2)
Multiple sheet feed involving dragged trailing sheet(s) (sensor 4 failure) occurred during paper
transport.
Multiple sheet feed involving dragged trailing sheet(s) (abnormal A/D value when postfeed opera-
tion is not operating) occurred during paper transport.
Multiple sheet feed involving dragged trailing sheet(s) (sensor 4 failure) occurred during paper
transport.
Multiple sheet feed involving dragged trailing sheet(s) (abnormal A/D value when postfeed opera-
tion is not operating) occurred during paper transport.
443 X12 Feed tray 2 separation error
The FL transfer sensor 1 activated at the feed tray 2 paper feed timing or on receiving a feed tray
setting command.
444 X11 Release request command timeout
Release request command was not issued by the main unit within the specified interval after noti-
fication of completion of paper feeding from a tray.
500 S09 Auto fence timeout (fence check)
[Movement complete] was not received during the fence moving operation within the specified
interval.
501 W07 Paper guide HP reset timeout
The paper guide HP sensor fails to activate during a paper guide HP reset.
502 W07 Paper guide HP failure timeout
The paper guide HP sensor fails to deactivate during movement of paper guide.
503 W07 Paper guide limit position movement timeout
The paper guide limit sensor fails to activate when the paper guides move to their limit positions.
504 W07 Paper guide limit position failure timeout
The paper guide limit sensor fails to deactivate during movement of paper guide.
505 W07 Paper stopper HP reset timeout
The paper stopper HP sensor fails to activate during paper stopper HP reset.
506 W07 Paper stopper HP position failure timeout
The paper stopper HP sensor fails to deactivate during movement of paper stopper.
507 W07 Paper stopper limit position failure timeout
The paper stopper limit sensor fails to activate when the paper stopper moves to its limit position.
508 W07 Paper stopper limit position failure timeout
The paper stopper limit sensor fails to deactivate during movement of paper stopper.
509 S09 Paper guide sensor error
The paper guide HP sensor and limit sensor have activated simultaneously.
510 S09 Paper stopper sensor error
The paper stopper HP sensor and limit sensor have activated simultaneously.
511 S08 PS7R controller system error.
PS7R controller system is in abnormal condition.
512 S08 PS7R controller HDD access error.
Unable to access to the PS7R controller HDD.
513 W08 PS7R controller HDD full.
PS7R controller HDD fully used.

E l e c t r i c a l P a r ts L i s t
CHA PT E R 13 : El e c tri c a l P a rts L i s t
CONTENTS
13 - 1
HC50 00 20 05/12 (R ev. 3.0 )
1.Assembly sections
1-1.Cove rs
No. Name Test mode

1 Control panel 8.1.8.2 LCD operational check
8.1.8.3 LED operational check
8.1.8.4 Buzzer operational check
2 Top cover
3 Ink cover
4 Right cover
5 Left cover
6 Rear cover
7 Front door R (Set SW) 8.2.1.1 Status check
8 Front door L (Set SW) 8.2.1.1 Status check
9 Inner cover 1
10 Inner cover 2
11 Inner cover 3
12 Support bar
13 Cooling fan 1 8.1.6.16 Operational check / 8.2.9.14 Connection check
14 Cooling fan 2 8.1.6.16 Operational check / 8.2.9.14 Connection check
15 Inner cover 4

1-2. Sta ndard pa per feed tray sec tion
No. Name Test mode

1 Paper size detection sensor 8.2.2.5 Operational check
2 Paper detection sensor 8.2.2.5 Operational check
3 Paper width sensor 8.2.2.6 Operational check
4 Elevator motor 8.1.1.1 Operational check
8.1.1.2 Button LED operational check
8.1.1.3 Elevator servo
13 - 3
HC50 00 20 05/12 (R ev. 3.0 )
1-3.Regi stratio n roller sec tion
No. Name Test mode

1 Registration sensor 8.2.4.1 Status check
2 Duplex belt OUT sensor 8.2.4.7 Status check
3 Switchback door SW
4 Registration roller lower
5 Registration roller upper
6 Switchback unit upper
7 Switchback unit lower
8 Switchback drive roll
9 Switchback door unit
10 Top edge sensor 8.2.4.2 Status check
11 Top edge LED
12 Multiple feed sensor (send)
13 Multiple feed sensor (receive) 8.1.3.22 Sensor light intensity check
14 Switchback sensor 8.2.4.8 Status check

1-4.Side registration unit section
No. Name Test mode

1 Side registration unit
2 CCD
3 Paper lift detection sensor 8.2.4.3 Status check
4 CIS PCB
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HC50 00 20 05/12 (R ev. 3.0 )
1-5.F lipp er secti on
No. Name Test mode

1 Flipper unit
2 Flipper gate
3 Star wheel
4 Flipper roller upper
5 Flipper roller lower
6 Counter 8.1.8.1 Operational check
8.2.11.2 Connection check
7 Flipper gate solenoid 8.1.3.12 Operational check / 8.2.4.12 Connection check

1-6. Dup lex u nit inlet section
No. Name Test mode

1 Star wheel assembly DX
2 Exit sensor 8.2.4.4 Status check
3 Flipper sensor 8.2.4.5 Status check
4 Duplex belt IN sensor 8.2.4.6 Status check
5 Duplex roller
6 Nip roller
13 - 7
HC50 00 20 05/12 (R ev. 3.0 )
1-7.Exit uni t sec tion
No. Name Test mode

1 Wing HP sensor 8.2.5.1 Status check
2 Exit motor encoder 8.2.5.2 Status check
3 Exit unit
4 Exit motor 8.1.3.20 Unit operation
5 Wing motor unit 8.1.3.21 Unit operation
6 Timing belt
7 Sponge roller
8 Wing front
9 Wing rear
10 Exit unit cover

1-8. Dup lex u nit secti on
No. Name Test mode

1 Duplex unit
2 Duplex belt upper
3 Duplex belt lower
4 Duplex unit gear
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HC50 00 20 05/12 (R ev. 3.0 )
1-9.T ran sfer uni t se ction
No. Name Test mode

1 Transfer unit
2 Transfer belt
3 Transfer belt encoder 8.1.3.1 Unit operation
4 Transfer belt motor 8.1.3.1 Unit operation
5 Cleaning roller
6 Suction fan 8.1.3.1 Unit operation
8.1.3.8 Suction fan 1 operation
7 Transfer unit upper position sensor

1-10 .Cl eanin g uni t se ction
No. Name Test mode

1 Ink pan sensor left 8.2.7.1 Status check
8.1.5.1 Unit operation
2 Ink pan sensor right 8.2.7.1 Status check
8.1.5.1 Unit operation
3 Suction nozzle HP sensor 8.2.7.2 Status check
4 Transfer unit suction position sen- 8.2.6.1 Status check
sor
5 Cleaning unit
6 Ink pan motor 8.1.5.1 Unit operation
7 Cleaning motor 8.1.5.2 Unit operation
8 Suction head
9 Cap
10 Star wheel unit
11 Torque limiter
13 - 11
HC50 00 20 05/12 (R ev. 3.0 )
1-11. Ink c artrid ge ho lder section
No. Name Test mode

1 INK cartrige holder
2 Bottle joint K
3 Bottle joint C
4 Bottle joint M
5 Bottle joint Y
6 Ink fuse solenoid
7 Ink cover sensor 8.2.1.3 Status check
8 Ink path open sensor 8.2.8.2 Status check
9 Receiver PCB
10 R/W PCB 8.2.8.1 Status check

1-12 .Ink res ervo ir secti on
No. Name Test mode

1 Reservoir K 8.1.5.4 K Pressure valve operation
8.1.6.2 K Ink fuse valve operation
8.1.6.6 K Reservoir air open valve operation
8.2.8.3 K Reservoir ink sensor status check
2 Reservoir C 8.1.5.5 C Pressure valve operation
8.1.6.3 C Ink fuse valve operation
8.1.6.7 C Reservoir air open valve operation
8.2.8.3 C Reservoir ink sensor status check
3 Reservoir M 8.1.5.6 M Pressure valve operation
8.1.6.4 M Ink fuse valve operation
8.1.6.8 M Reservoir air open valve operation
8.2.8.3 M Reservoir ink sensor status check
4 Reservoir Y 8.1.5.7 Y Pressure valve operation
8.1.6.5 Y Ink fuse valve operation
8.1.6.9 Y Reservoir air open valve operation
8.2.8.3 Y Reservoir ink sensor status check
5 Overflow tank
6 Pressure chamber
7 Pressure pump 8.1.5.3 Operational check
8 Pressure pump sensor 8.2.7.3 Status check
9 Overflow sensor 8.2.7.5 Status check / 8.2.7.8 Connection check
13 - 13
HC50 00 20 05/12 (R ev. 3.0 )
1-13. Print head secti on
No. Name Test mode

1 Print head 8.2.9.1-8.2.9.12 Head temperature check
8.2.9.13 Heat sink temperature check
2 Head drive PCB
3 Ribbon cable
4 Head joint valve
5 ID unit 8.1.6.14 KC DST heater operation
8.1.6.15 MY DST heater operation
8.2.8.4 ID unit ink sensor status check
8.2.8.5 ID unit inside temperature check
8.2.8.7 ID unit connection check
6 ID electromagnetic valve 8.1.6.10 K DST air open valve operation
8.1.6.11 C DST air open valve operation
8.1.6.12 M DST air open valve operation
8.1.6.13 Y DST air open valve operation

1-14 .Po wer su pply unit & Suc tion chamb er s ectio n
No. Name Test mode

1 Waste ink sensor upper 8.2.7.6 Status check
2 Waste ink sensor lower 8.2.7.6 Status check
3 Suction chamber 8.2.7.4 Sensor status check
(Suction chamber sensor)
4 Suction pump unit 8.1.5.8 Operational check
8.2.4.16 Cooling fan 1 connection check
8.2.4.17 Cooling fan 2 connection check
5 Suction tube
6 Pump filter
7 Power supply
8 FUSE1 250V T5AH
9 FUSE2 250V T6.3AH
10 Waste ink tank
13 - 15
HC50 00 20 05/12 (R ev. 3.0 )
1-15. PCBs
No. Name Test mode

1 ORIP PCB (IP PCB) 5.10.1 CPU version check
2 ORMC PCB (MC PCB) 5.10.2 CPU version check
3 Main motor control PCB
4 ORCNL PCB 8.2.11.3 Connection check
(Paper feed side relay PCB)
5 ORCNR PCB
(Exit side relay PCB)
6 FUSE3
7 Dust fan
8 HC control PCB
9 PCB box cover
10 Transfer belt motor control PCB

1-16 .Drive secti on
No. Name Test mode

1 Transfer unit lower position sensor
2 Switchback sensor 8.2.4.8 Status check
3 Lift gear unit 8.1.4.1 Elevator clutch operation / 8.1.4.2 Elevator unit
operation
8.2.6.2 Elevator clutch connection check
4 Lift worm gear
5 Main motor 8.1.3.1 Unit operation
6 Switchback motor 8.1.3.16 Unit operation
7 Switchback clutch 8.1.3.15 Operational check / 8.2.4.13 Connection check
8 Registration brake 8.1.3.5 Operational check / 8.1.3.7 Unit operation
9 Registration clutch 8.1.3.4 Operational check / 8.1.3.6 Unit operation
10 Paper feed clutch 8.1.3.3 Operational check / 8.2.4.9 Connection check
11 Duplex clutch unit 8.1.3.13 Operational check / 8.1.3.14 Unit operation
12 Duplex drive gear
13 Idler P
14 Timing belt
to
18
19 Flipper cover SW
20 Exit sensor 8.2.4.4 Status check
21 Flipper sensor 8.2.4.5 Status check
22 Duplex belt IN sensor 8.2.4.6 Status check
23 Re-pickup clutch 8.1.3.17 Clutch operation / 8.1.3.18 Brake operation
Re-feed brake 8.1.3.19 Unit operation / 8.2.4.15 Brake connection check
13 - 17
HC50 00 20 05/12 (R ev. 3.0 )

CHAPTER 14: PCBs and Schematic diagrams
CONTENTS
14 - 1
HC50 00 20 05/12 (R ev. 3.0 )
1.Role of PCB
Role of PCB
PCB Role
Power supply Power supply
Control panel Control of the panel display, Key input
ORIP PCB Image data processing and control of the print head
ORMC PCB Drive and control of the mechanism
HC control PCB Control of the ink cartridge section, I/F between option(FL)
RD/WR PCB I/F between Ink Tag of the Ink cartridge
ORCNR PCB Exit side relay PCB
ORCNL PCB Paper feed side relay PCB
Transfer motor control PCB Drive and control of the Transfer motor
Main motor control PCB Drive and control of the Main motor
Head drive PCB Drive and control of the Print head (KCMY)
CIS PCB Control the CCD sensor
AF Control PCB Drive and control the Exit paper fence
FL Power supply Power supply(FL)
FL Control PCB Drive and control of the FL section
Rear side 1
Control panel
RD/WR PCB
ORCNR PCB CIS PCB
(K)
Transfer motor control PCB (C)
(M)
(Y)
AF Control PCB
Head drive PCB
Power supply

Rear side 2
Main motor control PCB

ORMC PCB
ORIP PCB
HC Control PCB
FL Control PCB
ORCNL PCB
FL Power supply
14 - 3
HC50 00 20 05/12 (R ev. 3.0 )
2.Power Supply Unit
Power Supply Unit
Fuse
Fuse No. Voltage Connection

F11 +24V ORMC PCB
250V 6.3A
F12 +24V ORMC PCB
250V 6.3A
F13 +24V ORIP PCB
250V 6.3A
F15 +38V Main motor
250V 5A
F16 +38V Transfer belt motor
250V 5A
F17 +38V Head drive PCB (K)
250V 5A
F18 +38V Head drive PCB (C)
250V 5A
F19 +38V Head drive PCB (M)
250V 5A
F20 +38V Head drive PCB (Y)
250V 5A

3.Notes at the time of ORIP PCB exchange
The parameter of head adjustment etc. is recorded on the NVRAM installed on the ORIP PCB. The
printing operation is based on the parameter recorded within the NVRAM.
It is possible to save the same parameter for backup in another memory (flash memory mounted on
the ORIP PCB).
When the parameter is changed through adjustment, it should be saved for backup in this
memory.
When a failure occurs on the NVRAM, such as parameter loss, a much time is needed to re-do all the
adjustments. If a backup of the parameter is saved on the ORIP PCB, the lost parameter on the
NVRAM can be re-written in matter of seconds.
Follow the instruction given below in replacing the ORIP PCB and NVRAM.
CAUTION:
• NVRAM on the ORIP PCB includes a battery.
• Danger of explosion if battery is incorrectly replaced.
• Replace only with the same or equivalent type recommended by the manufacturer.
• Dispose of used batteries according to the manufacturer's instructions.
* When exchanging the ORIP PCB or NVRAM, wear a hand strap to remove the static electricity to prevent
damaging of these electric parts by the static electricity.
< Exchanging ORIP PCB >

(1) Remove the existing ORIP PCB from the machine.
(2) Remove the NVRAM, which is shown by the yellow colored arrow mark on the photograph
above, from the existing ORIP PCB, carefully not to damage the connecting legs.
(3) Attach the removed NVRAM on the new ORIP PCB.
(4) Attach the new ORIP PCB on the machine.
(5) Power ON the machine and go into SE-Mode (Test Mode).
(6) Select the Test Mode [8.5.6.1 Adjustment value storage] and activate. This will store the param-
eter on the NVRAM into the new ORIP PCB as a backup.
< Exchanging NVRAM >
This process will not work unless the parameter recorded in the NVRAM was backed up on the ORIP
PCB before the NVRAM broke.
(1) Remove the existing NVRAM from the ORIP PCB.
(2) Attach the new NVRAM on the ORIP PCB.
14 - 5
HC50 00 20 05/12 (R ev. 3.0 )
(3) Power ON the machine and go into SE-Mode (Test Mode).
(4) Select the test mode [8.5.6.2 Adjustment value loading] and activate. This will write the backed
up parameter on the ORIP PCB onto the new NVRAM.

PC Bs a nd S c h em at ic d i a g ra ms
4 . D o w n l o ad i n g / U p g r a d i ng t h e m ac h i n e p r o g r a m f i r m w a r e
Preparation
Following items are required to upgrade HC5000 and PS7R / PS7R9000 firmware.
• Laptop PC
• 512MB Compact Flash Card (CF Card)
• CF Card Reader with USB2.0 port.
(1) Upgrading HC5000 Firmware
1) Turn OFF the HC5000 power by pressing the soft-switch, and then the main power switch.
2) Disconnect Touch Panel and Scanner from PS7R / PS7R9000 if these optional units are
connected.
3) Make sure that HC5000 is correctly connected to the PS7R / PS7R9000.
4) Copy new Firmware program (PLALL***.dl2) to an empty CF Card. Do not place any other
data in the CF Card.
5) Set the CF Card in CF Card Reader.
6) Plug the CF Card Reader to USB Port No.1 on PS7R.
* If PS7R9000 is used, the USB Port number does no matter - use any available USB port.
7) Turn ON the main power switch of HC5000.
8) Turn ON the soft-switch on the HC5000 operation panel.
* Make sure not to turn OFF the power until the firmware upgrading is completed.
9) The HC5000 operation panel will ask [Update Firmware ?]. Press O.K. Key.
10) When the firmware upgrading is finished, the message [Downloading Completed Restart
Printer] will be shown on the panel display.
11) Confirming that the PS7R / PS7R9000 power is OFF, turn OFF the HC5000 main power
switch.
12) Disconnect CF Card Reader from PS7R / PS7R9000.
(2) Upgrading HC7R / HC7R9000
1) Confirm that PS7R / PS7R9000 power and HC5000 main power is OFF.
2) Disconnect PS7R / PS7R9000 completely free from HC5000. Only the power cable to
PS7R / PS7R9000 should be connected and plugged to an independent power supply
socket.
3) Copy new Firmware program (ps7r***.tgz) to an empty CF card. Do not place any other
data in the CF Card.
4) Set the CF Card in CF Card Reader.
5) Plug the CF Card Reader to USB Port No.1 on PS7R.
* If PS7R9000 is used, the USB Port number does no matter - use any available USB port.
6) Turn ON the PS7R / PS7R9000 by pressing the power button on the unit.
* Make sure not to turn OFF the power until the firmware upgrading is completed.
7) The LED buttons on the unit starts to flash and the firmware downloading starts.
8) The firmware downloading is finished when the LED flashing ends and only the Ready LED
(green) lights up.
9) Press the power button PS7R / PS7R9000 to shut OFF the power.
10) Disconnect CF Card Reader from PS7R / PS7R9000.
(3) Confirming the firmware download
1) With the HC5000 and PS7R / PS7R9000 power OFF, correctly connect HC5000 and PS7R
/ PS7R9000.
2) Turn ON the HC5000 main power switch, and then press the soft-switch on the HC5000.
3) After the machine starts up completely, use menu No. [5.6.1 Config Info Print - System
Information] to print the Status List Page.
4) Check and confirm that the printout indicates the new upgraded firmware versions on both
the System and Main program columns of the printout.
5) If the optional Touch-Panel and Scanner are to be connected, turn OFF the machine cor-
rectly and connect those optional units onto the PS7R / PS7R9000.
14 - 7
HC50 00 20 05/12 (R ev. 3.0 )
5.Exchange of ORMC (mechanical control) PCB

(2) Remove the PCB box cover.
* Wear a hand strap to avoid damaging the PCB by static electricity.
(3) Disconnect the connectors from the ORMC PCB.

(4) Remove six screws.
(5) Slide the ORMC PCB to the left to disconnect it from the HC control PCB joint connector.

(6) Install the new ORMC PCB on the PCB box, being careful not to scratch the rear surface of the
PCB against the PCB box frame.
* When mounting the ORMC PCB onto the PCB box, be careful not to scratch the rear surface of the PCB
against the sharp edges on the PCB box, becareful especially with the extended edges on the PCB box
frame. If the back of the PCB is scraped against the sharp edges, the IC chips on the reverse side of the
PCB will be damaged. If the IC chips on the reverse side is damaged, the PCB becomes a waste.
Be careful of the edges.
IC chips on the reverse side of the PCB
14 - 9
HC50 00 20 05/12 (R ev. 3.0 )
6.Schematic
Schematic
A1 block
32 32
J15 J64
PS7R USB J14
USB IP PCB
Controller I/F
I/F MC P501 26
ID unit air open valve (K)
I/F
P181 J53
J17 ID unit air open valve (C) P502
D1 block Distributor aria
ID unit air open valve (M) P503
P504
ID unit air open valve (Y)
P544 P505
ID unit ink sensor (K)
P625 P154
Paper emerge
J154 P151 40 P545 P540
detection ID unit ink sensor (C)
sensor J151 J16
CIS PCB P546 P506
CIS ID unit ink sensor (M)
From P206 P155 I/F
J155 J152 P547 P541
J153 ID unit ink sensor (Y)
P507
P152 P153 P586
Head Cooling fan(KC)
P508
P161 P162 Head Cooling fan(MY)
CIS L CIS R P581 P580
Elevator motor
(CCD) (CCD)
B1 block
J65
P562 P552
Ink fuse solenoid PRH
P851 P564 I/F
P853 8 Ink open sensor
6
Ink heater 1 J10 P563
Ink cover sensor
Distributor thermistor 1 HC control PCB
G1 block MF paper feed
Heater
P852 Thermistor
G2 block Option
P854 6
Ink heater 2 P561 P551
Receiver R/W PCB
Distributor thermistor 2 PCB
P512 P510 P509
J54
signal
P808 12 Main
Main motor Main motor control PCB motor
PWR
P513 P511 14
ORIP PCB OR
P516 P514 P533 J61
F
signal P809
Transfer motor control BP motor
Transfer motor
PCB
PWR
P517 P515
D2 block
P500 40 J52
Control panel
panel
C1 block 22
J62
Power control
10 P812
J12
Power
A2 block control POWER SUPPLY
P83
P122 80 24V 0
HEAD * 12 J3 (pump) 5V 24V 38V
Head driver PCB K HDR I/F P801 P802 P803 P810
Thermistor
P123 P804
P828 P824
80 Scraper cover SW
P122
HEAD * 12 J4
Head driver PCB C P805 P825 P821
HDR I/F Front door L SW
P826 P822 P829

P122 80 Front door R SW
J5
HEAD * 12 P823
Head driver PCB M HDR I/F P827
P806 Flipper cover SW
P813
80 J6 MF paper
P122 feed
HEAD * 12 HDR I/F J7
P814 J51 Powe
Head driver PCB Y P807 Power supply P815 P816 P817
Thermistor
P123 MF door safety SW
A3 block

E1 block
32
J64 P201 P202 P601 P634
J201
CNL PCB J57 J202 Elevator LED
IP PCB I/F 24 D1 block
I/F P602 P631
P203
P518 Paper feed pressure sensor
Dust fan 1 J203
J53 P632 Elevator upper limit sensor
P582 A
Dust fan 2
Distributor aria P633 Elevator upper limit sensor
J55
P519 Pickup clutch B
Paper feed P634
Duplex P520 Feed tray button
Registration clutch
Pressure P603
P521 P204
Registration brake J204 Paper width sensor
P522 P570 Paper size detection sensor
Duplex clutch
P571 Paper detection sensor
Re-pickup clutch
P572 P205 P607
Re-pickup brake J205 Elevator lower limit sensor
P525
Platen elevator clutch Remaining paper volume A
Remaining paper volume B
J206 P206 P608 P617

P531 ORCNL PCB Registration sensor
Switchback motor
P611 Multiple Feed sensor
P583 (receive)
Switchback clutch
P610
Multiple Feed sensor (send)
J65 P614 P612
Top edge LED
PRH P620 Transfer unit suction
I/F position sensor
to CIS PCB
P626
P615
10 Duplex belt OUT sensor
P586 Paper feed tray upper P616 P625
P584
J63 Switchback sensor
safety SW
P585 Paper feed tray lower P207
Elevator motor P613
safety SW Pressure pump
inter lock
J207 P623
Pressure pump sensor
P624 Transfer unit lower position
J54 sensor
P630 P621
2 Main Top edge sensor
5 P532 P587 Transfer motor-axis Transfer unit upper position
motor J56 P622
encoder sensor
axis-encoder
F2 block
ORMC PCB 28 P251 P254
P705
J61 J58 J251 J254 Overflow tank sensor
FW6702
20 P252
BP motor J59 J252
24 P253 P707
J60 J253 Suction chamber sensor
P708
Reservoir P701 P258 Counter
Ink fuse valve(K) J258 P255
P709
J255 Wing HP sensor
Pressure valve(K)
CNR PCB P710
Wing motor
0 J52 I/F Air open valve (K)
P711
Exit motor
panel Ink sensor(K)
P712
P734 Exit motor encoder
P831 P713
Reservoir Exit sensor
P702
2 Ink fuse valve(C) P832 P714
J62 Flipper sensor
Pressure valve(C)
P833 P715
Power control Duplex belt IN sensor
Air open valve (C)
P716
Flipper gate solenoid
Ink sensor(C) P717 P718 P811
P735 Suction pump
Reservoir ORCNR PCB Suction pump trouble

P703
detection
Ink fuse valve(M) P720
Waste ink sensor U
Pressure valve(M) P721
Waste ink sensor L
Air open valve (M)
Ink sensor(M) P256 P722 P723

P736 J256 Blower fan 1
Reservoir P704 P724
Blower fan 2
Ink fuse valve(Y)
P725
Blower fan 3
Pressure valve(Y)
P726
Blower fan 4
Air open valve (Y)
P257 P727
Ink sensor(Y) P728 Ink pan sensor 1
J257
P737 P729 Ink pan sensor 2
F1 block P730
Ink pan motor
J51 Power supply
P731 Cleaning motor
P732 Suction nozzle sensor
14 - 11
HC50 00 20 05/12 (R ev. 3.0 )
PHR-7
P161 1 AOUT 1 P152
2 GND 2 P151 1 CN CHECK 1 P16
CIS L 3 +3.3V 3 2 +3.3VMIP 2
4 CISSI 4 3 +3.3VMIP 3
5 CISCLK 5 4 GND 4
(CCD) 6 LEDG 6 5 GND 5
7 +24V 7 6 DISD0 6
7 DISD1 7
8 DISD2 8
9 DISD3 9
10 DISD4 10
11 DISD5 11
12 DISD6 12
PHR-8 13 DISD7 13
P162 1 AOUT 1 P153 14 GND 14
2 GND 2 15 ADCLKP 15
16 ADCLKN 16
CIS R 3 +3.3V 3
17 SHDP 17
4 CISSI 4
5 CISCLK 5 18 SHDN 18
(CCD) 6 LEDG 6 19 SHPP 19
7 +24V 7
CIS PCB 20 SHPN 20
8 21 CISSDIP 21
22 CISSDIN 22
23 CISSCKP 23
24 CISSCKN 24
25 CISSIP 25
26 CISSIN 26
27 CISCLKP 27
28 CISCLKN 28
29 GND 29
30 OUTEBX 30
Paper P625 PHR-4
31 INPCLP 31
1 +5V 1 P154
emerge 2 PATASNSX 2
32 CLPOB 32
33 CISA0 33
detection 3 GND 3
34 CISA1 34
sensor 4
35 CISWRT 35
36 CISRDO 36
37 LEDEBLX 37
38 VCC_24V 38
39 GND 39
40 GND 40
P853 1 HEATER6 1 +24V 1 P10

Ink heater 1 2 HEATER5 2 INKHEAT1 2
P851
P851
THM 4 3 +24V 3
THM 3 4 INKHEAT2 4
2 5 DISTTH1 5
1 6 GND 6
DISTTH2 7
GND 8
Distributor thermistor E1
E2
1
P854 1 HEATER6 1
Ink heater 2 2 HEATER5 2
P852
P852
THM 4 3
THM 3 4
2 5
1 6
Distributor thermistor E1
E2
2

1 P16
2 1 CN CHECK
3
P14 2 GND
4 3 MCTXDP
5 4 MCTXDN
6 5 MCSCKP
7 6 MCSCKN
8 7 GND
9 8 GND
10 9 MCRXDP
11 10 MCRXDN
12 11 MCSRQP
13 12 MCSRQN
14 13 ENC600P ORMC PCB
15 14 ENC600N P64
16 15 PSTRGP
17 16 PSTRGN (D1/2)
18 17 GND
19 18 GND
20 19 PRHTXDO
21 20 PRHRXDI
22 21 MCRSV1
23 22 WKLEDX
24 23 MCLATO
25 24 SLPLED1X
26 25 SLPLED2X
27 26 POWERINTX
28 27 WAKEUPINTX
29 28 IP-RDY
30 29 PRH-RDY
31 30 GND
32 31 GND
33 ORIP PCB 32 GND
34
35
36
37
38
39
40
1 ZWKUP 1 P181
P17 2 2
3 3
4 COM 4 PS7R
5 5 Controller
6 6
+24V 1 P10
INKHEAT1 2
+24V 3
INKHEAT2 4
DISTTH1 5
GND 6
DISTTH2 7
GND 8
A1/3
14 - 13
HC50 00 20 05/12 (R ev. 3.0 )
POWER SUPPLY +38V 1 P804 P122 A1 A40 P3

P803 A2 A39
GND 2 A3 A38
(C1/1) A4 A37
A5 A36
A6 A35
A7 A34
A8 A33
A9 A32
A10 A31
A11 A30
A12 A29
A13 A28
A14 A27
A15 A26
A16 A25
A17 A24
A18 A23
A19 A22
A20 A21
A21 A20
A22 A19
A23 A18
A24 A17
A25 A16
A26 A15
A27 A14
PHR-2 A28 A13
E1 HDRTH1 1 P123 A29 A12
Thermistor E2 HDRTH2 2 A30 A11
A31 A10
A32 A9
A33 A8
A34 A7
A35 A6
A36 A5
A37 A4
A38 A3
A39 A2
A40 A1 ORIP PCB
Head driver PCB K
B1 B40
B2 B39
B3 B38
B4 B37
B5 B36
B6 B35
B7 B34
B8 B33
B9 B32
B10 B31
B11 B30
B12 B29
B13 B28
B14 B27
B15 B26
B16 B25
B17 B24
B18 B23
B19 B22
B20 B21
B21 B20
B22 B19
B23 B18
B24 B17
B25 B16
B26 B15
B27 B14
B28 B13
B29 B12
B30 B11
B31 B10
B32 B9
B33 B8
B34 B7
B35 B6
B36 B5
B37 B4
B38 B3
B39 B2
B40 B1

P4 A40 A1 P122 P805 1 +38V

A39 A2
A38 A3 2 GND
A37 A4
A36 A5
A35 A6 POWER SUPPLY
A34 A7 P803
A33 A8 (C1/1)
A32 A9
A31 A10
A30 A11
A29 A12
A28 A13
A27 A14
A26 A15
A25 A16
A24 A17
A23 A18
A22 A19
A21 A20
A20 A21
A19 A22
A18 A23
A17 A24
A16 A25
A15 A26
A14 A27
A13 A28
A12 A29
A11 A30
A10 A31
A9 A32
A8 A33
A7 A34
A6 A35
A5 A36
A4 A37
A3 A38
A2 A39
ORIP PCB A1 A40
Head driver PCB C
B40 B1
B39 B2
B38 B3
B37 B4
B36 B5
B35 B6
B34 B7
B33 B8
B32 B9
B31 B10
B30 B11
B29 B12
B28 B13
B27 B14
B26 B15
B25 B16
B24 B17
B23 B18
B22 B19
B21 B20
B20 B21
B19 B22
B18 B23
B17 B24
B16 B25
B15 B26
B14 B27
B13 B28
B12 B29
B11 B30
B10 B31
B9 B32
B8 B33
B7 B34
B6 B35
B5 B36
B4 B37
B3 B38
B2 B39
B1 B40
A2/3
14 - 15
HC50 00 20 05/12 (R ev. 3.0 )
POWER P806 P122 P5

+38V 1 A1 A40
SUPPLY A2 A39
P803 GND 2 A3 A38
(C1/1) A4 A37
A5 A36
A6 A35
A7 A34
A8 A33
A9 A32
A10 A31
A11 A30
A12 A29
A13 A28
A14 A27
A15 A26
A16 A25
A17 A24
A18 A23
A19 A22
A20 A21
A21 A20
A22 A19
A23 A18
A24 A17
A25 A16
A26 A15
A27 A14
A28 A13
A29 A12
A30 A11
A31 A10
A32 A9
A33 A8
A34 A7
A35 A6
A36 A5
A37 A4
A38 A3
A39 A2
A40 A1
Head driver PCB M ORIP PCB
B1 B40
B2 B39
B3 B38
B4 B37
B5 B36
B6 B35
B7 B34
B8 B33
B9 B32
B10 B31
B11 B30
B12 B29
B13 B28
B14 B27
B15 B26
B16 B25
B17 B24
B18 B23
B19 B22
B20 B21
B21 B20
B22 B19
B23 B18
B24 B17
B25 B16
B26 B15
B27 B14
B28 B13
B29 B12
B30 B11
B31 B10
B32 B9
B33 B8
B34 B7
B35 B6
B36 B5
B37 B4
B38 B3
B39 B2
B40 B1

P6 P122 P807 POWER

A40 A1 1 +38V
A39 A2 SUPPLY
A38 A3 2 GND P803
A37 A4 (C1/1)
A36 A5
A35 A6
A34 A7
A33 A8
A32 A9
A31 A10
A30 A11
A29 A12
A28 A13
A27 A14
A26 A15
A25 A16
A24 A17
A23 A18
A22 A19
A21 A20
A20 A21
A19 A22
A18 A23
A17 A24
A16 A25
A15 A26 P123 1 HDRTH1 E1
A14 A27 2 HDRTH2 E2 Thermistor
A13 A28
A12 A29
A11 A30
A10 A31
A9 A32
A8 A33
A7 A34
A6 A35
A5 A36
A4 A37
A3 A38
A2 A39
A1 A40
ORIP PCB Head driver PCB Y
B40 B1
B39 B2
B38 B3
B37 B4
B36 B5
B35 B6
B34 B7
B33 B8
B32 B9
B31 B10
B30 B11
B29 B12
B28 B13
B27 B14
B26 B15
B25 B16
B24 B17
B23 B18
B22 B19
B21 B20
B20 B21
B19 B22
B18 B23
B17 B24
B16 B25
B15 B26
B14 B27
B13 B28
B12 B29
B11 B30
B10 B31
B9 B32
B8 B33
B7 B34
B6 B35
B5 B36
B4 B37
B3 B38
B2 B39
B1 B40
A3/3
14 - 17
HC50 00 20 05/12 (R ev. 3.0 )
P562
Ink fuse 1 +24V 1 P552
2 GND 2
solenoid 3
4
5
6
7
8
P563 1 +5V
2 SIGNAL
Ink cover sensor 3 GND
ORMC PCB
P564
1 +5V
2 SIGNAL HC control
Ink open sensor
3 GND PCB
P561
8 CNTCHK 1 P551
7 RUN 2
6 STOP 3
5 RST 4
R/W PCB 4 TXD 5
3 RXD 6
2 GND 7
1 VCC 8

ORMC PCB
B1/1
14 - 19
HC50 00 20 05/12 (R ev. 3.0 )
P812 1 PWCNTX 1 P12

2 PWFANX 2
3 PW24VX 3
4 PW38VX 4
5 PWACX 5
6 PW24CHKX 6
7 PW38CHKX 7
8 GND 8
9 ORIP_PCB
10 PWRRLY
11
12 GND
GND 1 P7
+5V 2
GND 3
+24V 4
POWER SUPPLY
P804
+38V 1
GND 2
Head driver PCB K
P802 1 GND
2 GND P805
3 GND +38V 1
4 GND GND 2
5 GND Head driver PCB C
6 GND
+24V 7 GND
8 +24V
9 +24V
10 +24V P806
11 +5V +38V 1
12 +5V GND 2
13 +5V Head driver PCB M
14 +5V
P807
+38V 1
GND 2
Head driver PCB Y
P803 1 GND
2 GND
3 GND
4 GND P808
5 GND +38V 1
6 GND GND 2
+38V 7 +38V 3
8 +38V 4
Main motor
9 +38V +5V 5 control PCB
P810 10 +38V GND 6
LIVE 1 POWER 11 +38V
NEUTRAL 2 12 +38V
SUPPLY
P801
P809
+38V 1
GND 2
2
1
P811 3
GND 1 4
Transfer motor
Suction
+24V 2 +5V 5 control PCB
pump GND 6
P813 P814
LIVE 1
P817
MF
2 1 ILPET 1 3 2 2 2
P815
P815
P816
P816
NEUTRAL 3 pape 2 2 2 1 1 1 MF door safety SW

4 r 3 ILPET 3 1
FG 5 feed
E1

1 P62
ILCVRL 2
3
4
ILCVRL 5
ILCVRR 6
7
8
ILCVRR 9
ILFR 10
11
12
ILFR 13
ILSB 14
15
16
ILSB 17 ORMC_PCB
PWRRLY 18
19
20
GND 21
22
+24V 1 P51
+24V 2
GND 3
GND 4
+5V 5
GND 6
P804
Head driver PCB K

1 2 3 4 5 6
P830
P805 P830
P827 1 ILFR
P823
2 6 5 4 3 2 1
Head driver PCB C Flipper cover SW 3 ILFR
P806
Head driver PCB M

P825 1 1 4 1 ILCVRL
1
P821
P821
2
P829
P829
Front door L SW 2 2 2 3 ILCVRL

2 3 ILCVRR
1 4 ILCVRR
P807
Head driver PCB Y
P826
P822
P822
1 1 1
P808 Front door R SW 2 2 2
Main motor
control PCB
P828 1 ILSB
P824
2
P809 Scraper cover SW 3 ILSB
Transfer motor
control PCB
C1/1
14 - 21
HC50 00 20 05/12 (R ev. 3.0 )
CN CHECK 1 P64 P57 1

GND 2 2
MCTXDP 3 3
MCTXDN 4 4
MCSCKP 5 5
MCSCKN 6 6
GND 7 7
GND 8 8
MCRXDP 9 9
MCRXDN 10 10
MCSRQP 11 11
ORIP PCB MCSRQN 12 12
P14 ENC600P 13 13
ENC600N 14 14
(A1/3) PSTRGP 15 15
PSTRGN 16 16
GND 17 17
GND 18 18
PRHTXD
19 19
O
PRHRXDI 20 20
MCRSV1 21 21
WKLEDX 22 22
MCLATO 23 23
SLPLED1
24 24
SLPLED2
X
25 25
POWERI
X
26 26
WAKEUPIN
NTX
27 27
TX
IP_RDY 28 28
PRH_RD
29 29
Y
GND 30 30
GND 31 31
GND 32 32
1 5 1 DISTKCCNTX 1 P53
ID unit ink
P544
2 4 2 KDISTFLX 2
P505
P505
sensor (K) 3 3 3 GND 3 P55 1

4 2 4 CDISTFLX 4 2
1 5 GND 5 3
GND 6 4
DISTMYCNTX 7 5
MDISTFLX 8 ORMC PCB 6
GND 9 7
1 4 1 YDISTFLX 10 8
P545
P540
P540
ID unit ink 2 3 2 GND 11 9

3 2 3 GND 12 10
sensor (C) 4 1 4 KDISTSOL 13 11
+24V 14 12
CDISTSOL 15 13
+24V 16 14
MDISTSOL 17 15
1 5 1 +24V 18 16
P546
ID unit ink 2 4 2 YDISTSOL 19 17

P506
P506
3 3 3 +24V 20 18
sensor (M) 4 2 4 HDFAN1 21 19
1 5 +24V 22 20
HDFAN2 23 21
+24V 24 22
ELVMTR1 25 23
ELVMTR2 26 24
1 4 1
ID unit ink
P547
P541
P541
2 3 2
sensor (Y) 3 2 3
4 1 4
P56 1
2
3
1 4
ID unit air open valve (K) 2 5
1
ID unit air open valve (C) 2
3
P63 1 P
2 X
3
4
1 5
ID unit air open valve (M) 2 6 P
7 X
8 P
9 X
1 10
ID unit air open valve (Y) 2
3
P
X
Head Cooling 1 5 1
2 4 2
fan(KC) 3 3
2 4
Head Cooling 1 1 5
2
fan(MY)
3 1
1 2 2
Elevator motor 2 1 3

P57 1 PFCNTX
2 ELVLED_PWR
3 ELEVLEDX
4 PFPRESSX
5 PFUPAX
6 PFUPBX
7 ELEVSW
8 PWVR1
9 PFSIZESNSX
10 PFEXISTSNSX
11 PFNAEMP
12 PFEMP
13 PFLOX
14 DFLED ORNCL PCB
15 PATASNSX P201
16 TOPLED
17 MNTPOSSNS (E1/1)
18 REVBLTSNSX
19 SBSNSX
20 REGSNSX
21 A_DFSNS1
22 TOPSNS
23 BPHPSNS
24 BPLIMSNS
25 ROTCHK
26 PUMP
27 GND
28 +24V
29 GND
30 +5V
31 GND
32 +5V
P55 1 FDCL 1
2 +24V 2 Pickup clutch
3 REGCL
4 +24V
5 REGBKCL
ORMC PCB 6 +24V 1
7 BPMVCL 2 Registration clutch
8 +24V
9 DUPCL
10 +24V
11 DUPFDCL 1
12 +24V 2 Registration brake
13 DUPBKCL
14 +24V
15 SWBCL
16 +24V 1 Platen elevator
17 DSTFAN1 2
18 +24V clutch
19 DSTFAN2
20 +24V
21 SWBKP1
22 SWBKDIS1 1 6 DUPCL 2
23 SWBKP2 2 5 +24V 1
P522
P522
24 SWBKDIS2 3 4 DUPFDCL
4 3 +24V
5 2 DUPBKCL
6 1 +24V
P587 2 Re-pickup
P56 1 +5V 1 1 1 1
clutch
P532
P532
2 ENCA 2 2 2 1 Switchback
3 ENCB 3 3 3 2
4 ENCZ 4 4 4
clutch
5 GND 5 5 5
GND 6 6 6
1
2 Dust fan 1 2 Re-pickup
Transfer motor-axis 1
encoder brake
P63 1 PFUPLIM
2 X 1
3 2 Dust fan 2
4
5
6 PFUPLIM
7 X 1
8 PFLOLIM 2
9 X 3
10 4
5
P531
6
PFLOLIM 7 Switchback motor
X 8
9
10
11
P586
1 4 PFUPLIMX 1 Paper feed tray upper
P584
P584
2 3 2
3 2 3 safety SW
4 1 PFUPLIMX
1 P585
2 Paper feed tray lower
D 1/2
3 safety SW
4
14 - 23
HC50 00 20 05/12 (R ev. 3.0 )
P512 1 H+ 1 P510
2 H- 2
3 Hv- 3 P509 1 BMCLK 1 P54
4 Hv+ 4 2 MBFG 2
Main motor 5 Hu- 5 3 MBM0 3
6 Hu+ 6 4 MBM1 4
control 7 Hw- 7 5 RESET OUT 5
8 Hw+ 8 Main motor control PCB 6 MBRDYX 6
9 FG 9 7 MBDOUT 7
1 FG 1 8 MBEMG 8
0 0 9 MBSCK 9
10 MBEBL 10
11 MBSDAT 11
P513 1 W 1 P511 12 GND 12
Main motor 2 V 2
power supply 3 U 3
P516 1 H+ 1 P514
2 H- 2 P533 1 DUPCLK 1 P61
3 Hv- 3 2 DUPFG 2
4 Hv+ 4 3 DUPM0 3
Transfer motor 5 Hu- 5 4 DUPM1 4
6 Hu+ 6 5 RESET OUT 5
control 7 Hw- 7 6 DUPRDYX 6
8 Hw+ 8 Transfer motor control 7 DUPDOUT 7
9 FG 9 PCB 8 DUPEMG 8
1 FG 1 9 DUPSCK 9
0 0 10 DUPEBL 10
11 DUPSDAT 11
12 GND 12
P517 1 W 1 P515 13
Transfer motor 2 V 2 14
power supply 3 U 3
1 1 P52 ORM
P500
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
ORPNL_PCB 20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
29 29
30 30
31 31
32 32
33 33
34 34
35 35
36 36
37 37
38 38
39 39
40 40

P58 1 +24V
2 +24V
3 +24V
1 P54 4 +24V
2 5 +24V
3 6 +24V
4 7 +5V
5 8 +5V
6 9 +5V
7 10 +5V
8 11 GND
9 12 GND
10 13 GND ORCNR PCB
11 14 GND P251
12 15 BLTCALENC
16 EXITSNSX (F1/2)
17 FLOTSNSX
18 FLOUTSNSX
19 DUPGTSOL
20 WEISTBTL
21 SUCPUMP1
22 SUCPUMPCHK1
23 CMBFLX
24 CMBCNTX
25 KSUCSELSOL
1 P61 26 WEISTNF
2 27 STOFSNSX
3 28 STOFCNTX
4 29 COUNT
5 30 COUNTCNTX
6
7
8
9
10
11 P59 1 BPFAN1
12 2 BPFAN2
13 3 BPFAN3
14 4 BPFAN4
5 INKPSNS1
6 INKPSNS2
7 INK1
8 INK2
9 NZP1 ORCNR PCB
10 NZDIS1 P252
1 P52 ORMC PCB 11 NZP2
2 12 NZDIS2 (F1/2)
3 13 NZHPSNS
4 14 WINGHP
5 15 WINGP1
6 16 WINGDIS1
7 17 WINGP2
8 18 WINGDIS2
9 19 EXITMTR
10 20 EXITENC
11
12
13
14
15
16 P60 1 KSUPSOL
17 2 KPURSOL
18 3 KRSVOPSOL
19 4 KSTNKFLX
20 5 STNKKCNTX
21 6 GND
22 7 CSUPSOL
23 8 CPURSOL
24 9 CRSVOPSOL
25 10 CSTNKFLX
26 11 STNKCCNTX ORCNR PCB
27 12 GND
28
P253
13 MSUPSOL
29 14 MPURSOL (F1/2)
30 15 MRSVOPSOL
31 16 MSTNKFLX
32 17 STNKMCNTX
33 18 GND
34 19 YSUPSOL
35 20 YPURSOL
36 21 YRSVOPSOL
37 22 YSTNKFLX
38 23 STNKYCNTX
39 24 GND
40
D 2/2
14 - 25
HC50 00 20 05/12 (R ev. 3.0 )
PFCNTX 1 P201
ELVLED_PWR 2
ELEVLEDX 3
PFPRESSX 4
PFUPAX 5
PFUPBX 6
ELEVSW 7
PWVR1 8 P202
PFSIZESNSX 9
PFEXISTSNSX 10
PFNAEMP 11
PFEMP 12
PFLOX 13
DFLED 14
PATASNSX 15 P203
ORMC PCB TOPLED 16
P57 MNTPOSSNS 17
(D1/2) REVBLTSNSX 18
SBSNSX 19
REGSNSX 20
A_DFSNS1 21
TOPSNS 22
BPHPSNS 23
BPLIMSNS 24
ROTCHK 25
PUMP 26
GND 27
+24V 28
GND 29
+5V 30
GND 31
+5V 32
P204
Multiple Feed P610 1 P206
2 DFLED 2
sensor 1 VCC 3
(send) GND 4
PATASNSX 5
VCC 6
GND 7
TOPLED 8
P155 3 9
CIS PCB 2 GND 10
(Paper emerge detection sensor) 1 BPLIMSNS 11 ORCNL_PCB
VCC 12
GND 13
REVBLTSNSX 14
VCC 15 P205
GND 16
P612 3 1 2 SBSNSX 17
2 2 1 VCC 18
Top edge LED 1 GND 19
REGSNSX 20
VCC 21
GND 22
DFSNS 23
Transfer unitP620 3 VCC 24
2
suction position 1
sensor
P207
P615 3 1 3
P626
P626
Duplex belt OUT 2 2 2

sensor 1 3 1
P625 3 1 3
Switchback 2 2 2
sensor 1 3 1
7 1
P617 3 GND 6 2
Registration 2 REGSNSX
5 3
P608
P608
sensor 1 VCC 4 4
GND 3 5
DFSNS 2 6
VCC 1 7
Multiple Feed P611 3

sensor 2
1
(receive)

1 P201
2
3
4
5
6
7
8 P202 1 ELVLED 1 2 ELVLED 1
9 2 2 1 2 P634
10 ELEVSW 3
11 GND 4 Elevator LED
12
13
14
15 P203 GND 3 P631
16 1 15 1 PFPRESSX 2 Paper feed
17 2 14 2 VCC 1
18 3 13 3
pressure sensor
19 4 GND 12 4
20 5 PFPRESSX 11 5
21 6 VCC 10 6
22 7 GND 9 7 GND 3 P632
23 8 PFUPAX 8 8 PFUPAX 2
24 VCC
Elevator upper limit
9 VCC 7 9 1
25 10 GND 6 10 sensor A
26 11 PFUPBX 5 11
27 12 VCC 4 1213
28 13 GND 3 14
29 14 ELEVSW 2 15 GND 3 P633
30 15 1 PFUPBX 2
31 VCC
Elevator upper limit
1
32 sensor B
P204 1 10 1 Paper width sensor

1 P206 2 GND 9 2
2 3 PP_WIDTH 8 3
3 4 VCC 7 4
P603
4 5 GND 6 5
5 6 PP_LNGTH 5 6 Paper size
6 7 VCC 4 7 detection sensor
7 8 GND 3 8
8 9 PP_EXIST 2 9
9 10 VCC 1 10
10 Paper detection
11 ORCNL_PCB sensor
12
13
14
15 P205 Elevator lower limit
16 1 VCC 1 9 sensor
17 2 PFLOX 2 8
18 3 GND 3 7
P607
19 4 VCC 4 6
20 5 PFEMP 5 5 Remaining paper
21 6 GND 6 4 volume B
22 7 VCC 7 3
23 8 PFNAEMP 8 2
24 9 GND 9 1
Remaining paper
volume A
P207 1 +24V 2 P613

2 PUMP 1 Pressure pump
3 GND
4 ROTCHK
5 VCC
6 GND
7 BPLIMSNS 3 P623
8 VCC 2
9 GND 1
Pressure pump
10 BPHPSNS sensor
11 VCC
12
13 TOPSNS
14 VCC 3 P624
2
1
Transfer unit lower
position sensor
3 P622
2 Transfer unit upper
1 position sensor
1 5 GND
2 4 BPHPSNS
P630
P630
3 3 VCC 3 P621
4 2 TOPSNS 2 Top edge
5 1 VCC 1
sensor
E1/1
14 - 27
HC50 00 20 05/12 (R ev. 3.0 )
+24V 1 P251 P258 1 KSUPSOL

+24V 2 2 +24V
+24V 3 3 KPURSOL
+24V 4 4 +24V
+24V 5 5 KRSVOPSOL
+24V 6 6 +24V
+5V 7 7 KSTNKFLX
+5V 8 8 GND
+5V 9 9 STNKKCNTX
+5V 10 10 GND
GND 11 11 CSUPSOL
GND 12 12 +24V
GND 13 13 CPURSOL
ORMC PCB GND 14 14 +24V
P58 BLTCALENC 15 15 CRSVOPSOL
EXITSNSX 16 16 +24V
(D2/2) FLOTSNSX 17 17 CSTNKFLX
FLOUTSNSX 18 18 GND
DUPGTSOL 19 19 STNKCCNTX
WEISTBTL 20 20 GND
SUCPUMP1 21 21 MSUPSOL
SUCPUMPCHK1 22 22 +24V
CMBFLX 23 P258 23 MPURSOL
CMBCNTX 24 24 +24V
KSUCSELSOL 25 25 MRSVOPSOL
WEISTNF 26 26 +24V
STOFSNSX 27 27 MSTNKFLX
STOFCNTX 28 28 GND
COUNT 29 29 STNKMCNTX
COUNTCNTX 30 30 GND
31 YSUPSOL
32 +24V
33 YPURSOL
34 +24V
35 YRSVOPSOL
BPFAN1 1 P252 36 +24V
BPFAN2 2 37 YSTNKFLX
BPFAN3 3 38 GND
BPFAN4 4 39 STNKYCNTX
INKPSNS1 5 40 GND
INKPSNS2 6
INK1 7
INK2 8
ORMC PCB NZP1 9
P59 NZDIS1 10 ORCNR PCB
NZP2 11
(D2/2) NZDIS2 12
NZHPSNS 13
WINGHP 14
WINGP1 15
WINGDIS1 16
WINGP2 17
WINGDIS2 18
EXITMTR 19
EXITENC 20
KSUPSOL 1 P253
KPURSOL 2
KRSVOPSOL 3
KSTNKFLX 4
STNKKCNTX 5
GND 6
CSUPSOL 7
CPURSOL 8
CRSVOPSOL 9
CSTNKFLX 10
ORMC PCB STNKCCNTX 11
P60 GND 12
MSUPSOL 13
(D2/2) MPURSOL 14
MRSVOPSOL 15
MSTNKFLX 16
STNKMCNTX 17
GND 18
YSUPSOL 19
YPURSOL 20
YRSVOPSOL 21
YSTNKFLX 22
STNKYCNTX 23
GND 24

P701 P701 2
1 KSUPSOL 1 1 KSUPSOL 1 Ink fuse valve(K)
2 +24V 2 0 +24V
3 KPURSOL 3 9 KPURSOL 2
4 +24V 4 8 +24V 1 Pressure valve(K)
5 KRSVOPSOL 5 7 KRSVOPSOL
6 +24V 6 6 +24V 2
7 KSTNKFLX 7 5 KSTNKFLX 1 Air open valve (K)
8 GND 8 4 GND
9 STNKKCNTX 9 3 STNKKCNTX
10 GND 1 2 GND 4 P734
11 CSUPSOL 0 1 3
12 +24V K CN 2 Ink sensor(K)
13 CPURSOL 1
14 +24V
15 CRSVOPSOL
16 +24V
17 CSTNKFLX
18 GND P702 P702 2
19 STNKCCNTX 1 1 CSUPSOL 1 Ink fuse valve(C)
20 GND 2 0 +24V
21 MSUPSOL 3 9 CPURSOL 2
22 +24V 4 8 +24V 1 Pressure valve(C)
23 MPURSOL 5 7 CRSVOPSOL
24 +24V 6 6 +24V 2
25 MRSVOPSOL 7 5 CSTNKFLX 1 Air open valve (C)
26 +24V 8 4 GND
27 MSTNKFLX 9 3 STNKCCNTX
28 GND 1 2 GND 4 P735
29 STNKMCNTX 0 1 3
30 GND C CN 2 Ink sensor(C)
31 YSUPSOL 1
32 +24V
33 YPURSOL
34 +24V
35 YRSVOPSOL
36 +24V P703 P703 2
37 YSTNKFLX 1 1 MSUPSOL 1
38 GND 2 0 +24V
Ink fuse valve(M)
39 STNKYCNTX 3 9 MPURSOL 2
40 GND 4 8 +24V 1
5 7 MRSVOPSOL Pressure valve(M)
6 6 +24V 2
7 5 MSTNKFLX 1
8 4 GND Air open valve (M)
9 3 STNKMCNTX
1 2 GND 4 P736
0 1 3
M CN 2
1 Ink sensor(M)
P704 P704 2
1 1 YSUPSOL 1 Ink fuse valve(Y)
2 0 +24V
3 9 YPURSOL 2
4 8 +24V 1 Pressure valve(Y)
5 7 YRSVOPSOL
6 6 +24V 2
7 5 YSTNKFLX 1 Air open valve (Y)
8 4 GND
9 3 STNKYCNTX
1 2 GND 4 P737
0 1 3
Y CN 2 Ink sensor(Y)
1
F 1/2
14 - 29
HC50 00 20 05/12 (R ev. 3.0 )
P722 P722
P723 1 BPFAN1 1 1 BPFAN1 1 P256
Blower fan 1 2 +24V 2 2 +24V 2
BPFAN2 3 3 BPFAN2 3
+24V 4 4 +24V 4
BPFAN3 5 5 BPFAN3 5
+24V 6 6 +24V 6
BPFAN4 7 7 BPFAN4 7
P724 1 +24V 8 8 +24V 8
Blower fan 2 2 9
10
P722ਛ⛮
(ๆᒁFAN)
P725 1
Blower fan 3 2
P726 1
Blower fan 4 2
P727 P727
P728 3 GND 15 1 GND 1 P257 ORCNR PCB
Ink pan sensor 1 2 INKPANSNS1 14 2 INKPANSNS1 2
1 +5V 13 3 +5V 3
GND 12 4 GND 4
INKPANSNS2 11 5 INKPANSNS2 5
+5V 10 6 +5V 6
P729 3 INK1 9 7 INK1 7
Ink pan sensor 2 2 INK2 8 8 INK2 8
1 NZP1 7 9 NZP1 9
NZDIS1 6 10 NZDIS1 10
NZP2 5 11 NZP2 11
NZDIS2 4 12 NZDIS2 12
P730 2 GND 3 13 GND 13
Ink pan motor 1 NZHPSNS 2 14 NZHPSNS 14
+5V 1 15 +5V 15
16
17
P731 4 18
3
Cleaning motor 2
1 P727
(Ink pan block)
P732 3
Suction nozzle 2
sensor 1

56 P254 1 STOFSNSX 1 P705

2 GND 2
3 STOFCNTX 3 Overflow tank sensor
4 GND 4
5
6
7 CMBFLX
8 GND
9 CMBCNTX 1 P707
10 GND 2 Suction chamber
11 COUNT 3
12 +24V 4
sensor
13 COUNTCNTX
14 GND
M1
1 1
P708
P708
2 2
3 3 Counter
4 4
P255 1 GND 1 P709

2 WINGHP 2 Wing HP sensor
57 ORCNR PCB 3 +5V 3
4 WINGP1
5 WINGDIS1
6 WINGP2
7 WINGDIS2 1 P710
8 EXITMTR 2
9 +24V 3 Wing motor
10 GND 4
11 EXITENC
12 +5V
13 GND
14 EXITSNSX 1 P711
15 +5V 2 Exit motor
16 GND
17 FLCTSNSX
18 +5V
19 GND 1 P712
20 FLOUTSNSX 2
21 +5V 3
Exit motor
22 DUPGTSOL encoder
23 +24V
24 SUCPUMP1
25 GND 1 4 1 P713
P831
P831
26 SUCPUMPCHK1 2 3 2
3 2
Exit sensor
27 GND 3
28 GND 4 1
29 WEISTBTL
30 +5V
31 GND 1 4 1 P714
P832
P832
32 WEISTNF 2 3 2
3 2 Flipper sensor
33 +5V 3
34 4 1
1 4 1 P715
P833
P833
2 3 2
3 2
Duplex belt IN sensor
3
4 1
1 P716
2 Flipper gate
solenoid
P717 P717 Suction pump P811

1 1 SUCPUMP1 1 1
P718
P718
GND 1
+24 B1/1
PS
2 0 GND 2 2 2
3 9 SUCPUMPCHK1 3 3 V
4 8 GND
5 7 GND
6 6 WEISTBTL
7 5 +5V 1 P720
8 4 GND 2 Waste ink sensor U
9 3 WEISTNF 3
1 2 +5V
0 1
P717ਛ⛮ 1 P721
2 Waste ink sensor L
3
F2/2
14 - 31
HC50 00 20 05/12 (R ev. 3.0 )
P813
1 CN1
LIVE 1 2
2 3
to Power supply NEUTR 3 FL Power supply 4
P810 AL 4 5
5 6
FG
E1
tray 1 A12 A12 V 1 CN2

A11 A11 OUT 2
Paper detection A10 A10 GND 3
sensor A9 A9 V 4
A8 A8 OUT 5
A7 A7 GND 6
tray 1 A6 A6 7
Paper size detection A5 A5 8
A4 A4 9
sensor A3 A3 10
A2 A2 11
A1 A1 12
tray 1 B1 B1 V 13
B2 B2 OUT 14
Tray volume sensor B3 B3 GND 15
1 B4 B4 V 16
B5 B5 OUT 17
B6 B6 GND 18
tray 1 B7 B7 V 19
Tray volume sensor B8 B8 OUT 20
B9 B9 GND 21
2 B10 B10 22
23
24
tray 1 CN
Paper width sensor
tray 2 A12 A12 V 1 CN3

A11 A11 OUT 2
Paper detection A10 A10 GND 3
sensor A9 A9 V 4
A8 A8 OUT 5
A7 A7 GND 6
tray 2 A6 A6 7
Paper size detection A5 A5 8
A4 A4 9
sensor A3 A3 10
A2 A2 11
A1 A1 12 FL control PCB
tray 2 B1 B1 V 13
B2 B2 OUT 14
Tray volume sensor B3 B3 GND 15
1 B4 B4 V 16
B5 B5 OUT 17
B6 B6 GND 18
tray 2 B7 B7 V 19
Tray volume sensor B8 B8 OUT 20
B9 B9 GND 21
2 B10 B10 22
23
24
tray 2 CN
Paper width sensor
tray 1 1 CN4
FL feed tray Elevator 2
motor 3
4
tray 2 5
FL feed tray Elevator
motor
Nip release solenoid 1 CN5
2
(FL front) 3
4
(FL rear)
1 CN6
FL multi-tray 1 2
pickup sensor 3
4
5
FL feed sensor 1 6
7
8
9
FL feed sensor 2 10
11
12
13
FL feed sensor 3 (receive) 14
FL feed sensor 3 (send)

CN7 1
2 tray 1 Upper limit sensor
3
4
5
6 tray 2 Upper limit sensor
CN8 1
FL Transfer motor
2
3 FG sensor
CN9 1
2 Transfer clutch 1
3
4
5
6
Transfer clutch 2
7
8
9 Transfer clutch 3
1
0
Tray 2 Pickup clutch
Tray 1 Pickup clutch
CN10 1
2
3
FL left cover SW
4
CN12 1
tray 1
2
3 Setup confirmation switch
4
5
FL control PCB 6 tray 2
7 Setup confirmation switch
8
P814 P817
CN13
P816
P816
1 ILPET 1 3 2 2 2
P815
P815
2 2 2 1 1 1 MF door safety SW
3 ILPET 3 1
1㨪18 to PRH PCB CN7

CN14
19 Nip release solenoid
20 (transfer)
21
22
23 Nip release solenoid
24 (transfer)
25
26
27
28 Transfer clutch 4
29
30
31
32
33
34 FL feed sensor 4
35
36
CN15
FL transfer motor
CN16
FL multi feed tray pickup
motor
G1/2
14 - 33
HC50 00 20 05/12 (R ev. 3.0 )
1 CN1
Exit tray paper detection 2
sensor 3
4
5
1 CN2 C
Paper guide base SW 2
(paper guide F)
1 CN3
Paper guide base SW 2
(paper guide F) 3
1 CN4
Paper guide HP sensor 2
3
4
5
6
7
Paper guide limit sensor 8
Paper guide base SW

(paper guide R)
AF control PCB
1 CN5
2
Paper stopper pulse motor 3
4
1 CN6
2
Paper guide pulse motor 3
4
1 CN7
2
Paper stopper HP button
1 CN8
Paper stopper HP sensor 2
3
4
5
Paper guide base SW

(paper stopper)

CN6
to HC control PCB
CN7
AF control PCB
G2/2
14 - 35
HC50 00 20 05/12 (R ev. 3.0 )

HC5000 Technical Manual

(Rev. 3.0)
Published December 2005
Reproduction and duplication prohibited
Edited and published by: Technical Training Center,
Riso Kagaku Corporation
The contents of this manual are subject to change

without notice to permit product improvements.

HC5000 Tech

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DANKA AUSTRALIA PTY. LTD.

Copyright: 2005 Riso Kagaku Corporation

RISO INTERNATIONAL GROUP

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

First paper feed section

Multi-tray paper feed section

Second paper feed section

Ink supply passages

Paper receiving section

Controller & power supply unit

Electrical Parts List

PCBs and Schematic diagrams

CHAPTER 1: Maintenance Notes

[ Handling of Lithium Battery ]

1. Never let the battery short-circuited.

[ Replacement of the Lithium Battery ]

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

1-2 RISO KAGAKU CORPORATION -Technical Training Center-

Important Safety Precautions

2) Protection of the machine:

(3) Always connect electrical connectors firmly.

1) To avoid electrical failure:

2) Protection of the electrical components:

Wire harness connector

THEN Press the center, firmly.

1-1.Gen eral precautions

* Never perform maintenance while the machine is operating.

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

1-4 RISO KAGAKU CORPORATION -Technical Training Center-

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

interrupt type (U-shaped) actuator type

1-6 RISO KAGAKU CORPORATION -Technical Training Center-

2-1. List of general tools

Type Size Shaft length, etc.

HEAD ANGLE JIG

Transfer unit support jig

Transfer belt stand jig

Interlock switch jig

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

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

Printer unit lifting jig

1-8 RISO KAGAKU CORPORATION -Technical Training Center-

Image adjustment utility software:

Notebook PC (commercially available)

Flatbed scanner (commercially available)

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

Cleaning wipes (commercially available)

Gloves (commercially available)

Vacuum cleaner (commercially available)

Binder clip (commercially available)

IPA (isopropyl alcohol) or equivalent

A4-size coated paper

1 - 10 RISO KAGAKU CORPORATION -Technical Training Center-

Syringe of about 20 ml in size (commercially available)

2-3. Period ical Ma inten ance

Part Name Maintenance Interval Reference

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

1 - 12 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 14 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 16 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 18 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 20 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 22 RISO KAGAKU CORPORATION -Technical Training Center-

1 - 24 RISO KAGAKU CORPORATION -Technical Training Center-