Registration Section

Chapter 6. Registration Section Contents 1. Mechanisms........................................................................................ 6-2 1-1. Basic Structure ................................................................................................ 6-2 1-2. Vertical Paper Feed Unit B Mechanism............................................................ 6-3 1-3. Vertical Paper Feed Unit A Mechanism............................................................ 6-4 1-4. Assist Action..................................................................................................... 6-4 1-5. Registration Roller Mechanism......................................................................... 6-7 1-6. Paper Position Detection Unit Mechanism....................................................... 6-7 1-7. Detection Mechanism for Leading and Trailing Edges..................................... 6-8

2. Disassembly..................................................................................... 6-11 2-1. Vertical Paper Feed Unit A............................................................................. 6-11 2-2. Vertical Paper Feed Sensor 5 (Vertical Paper Feed Unit A)........................... 6-11 2-3. Vertical Paper Feed Roller 5 (Vertical Paper Feed Unit A)............................. 6-12 2-4. Vertical Paper Feed Unit B............................................................................. 6-12 2-5. Vertical Paper Feed Sensor 1 (Vertical Paper Feed Unit B)........................... 6-13 2-6. Vertical Paper Feed Sensor 2 (Vertical Paper Feed Unit B)........................... 6-14 2-7. Vertical Paper Feed Sensor 3 (Vertical Paper Feed Unit B)........................... 6-14 2-8. Vertical Paper Feed Sensor 4 (Vertical Paper Feed Unit B)........................... 6-14 2-9. Vertical Paper Feed Roller 1 (Vertical Paper Feed Unit B)............................. 6-14 2-10. Vertical Paper Feed Roller 2 (Vertical Paper Feed Unit B)........................... 6-15 2-11. Vertical Paper Feed Roller 3 (Vertical Paper Feed Unit B)........................... 6-15 2-12. Vertical Paper Feed Roller 4 (Vertical Paper Feed Unit B)........................... 6-15 2-13. Internal Feed Paper Jam Door Interlock Switch (Vertical Paper Feed Unit B).......................... 6-15 2-14. Vertical Paper Feed Clutch 1........................................................................ 6-15 2-15. Vertical Paper Feed Clutch 2........................................................................ 6-16 2-16. Registration Motor Assembly........................................................................ 6-16 2-17. Registration Sensor (Send).......................................................................... 6-16 2-18. Registration Sensor (Receive)...................................................................... 6-17 2-19. Top Edge Sensor 1 (Send)........................................................................... 6-18 2-20. Top Edge Sensor 1 (Receive)...................................................................... 6-18 2-21. Registration Roller........................................................................................ 6-18 2-22. Guide Roller.................................................................................................. 6-20 2-23. Paper Position Detection Unit....................................................................... 6-20 2-24. Paper Lift Detection Sensor.......................................................................... 6-21 2-25. Paper Width Detection Sensor (FRONT & REAR)....................................... 6-22

3. Adjustment....................................................................................... 6-24 3-1. Adjustment to Make the Registration Roller and BP Unit Parallel.................. 6-24 3-2. CIS Adjustment............................................................................................... 6-24 3-3. Sensor Sensitivity Adjustment........................................................................ 6-28

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Registration Section

1. Mechanisms 1-1. Basic Structure The registration section transfers paper into the printing area from the internal or external paper feed unit or switchback unit. This section is comprised of vertical paper feed units B and A, the registration roller unit, and the paper position detection unit. Registration roller unit Paper position detection unit

Vertical paper feed unit A

Vertical paper feed unit B

Normal printing action 1) Registration rollers stop before paper from the feed or switchback sections are transferred further. 2) The leading edge of paper from the feed or switchback sections comes into contact with the registration rollers, which are stopped, making the front edge parallel to the registration roller shaft. 3) The leading edge of paper from the paper feed tray or internal paper feed section is detected by the registration sensor. If no paper is fed, the registration rollers do not rotate. 4) As rollers rotate at a specific speed, the straightened paper is held and then transferred with a specific force. 5) Multiple paper feeds are detected by top edge sensor 1. If a multiple paper feed occurs, the registration rollers stop rotating before the leading edge of paper reaches the print heads. 6) The registration rollers continue rotating at a specific speed until the trailing edge is clear of the registration rollers. 7) After a specific period once paper has cleared the registration rollers, the registration rollers stop rotating. 8) If paper jams other than non-feeds are detected, the registration rollers stop rotating.

Top edge sensor 1 (receive)

Registration sensor (receive)

Registration roller

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Registration Section

1-2. Vertical Paper Feed Unit B Mechanism Paper feeding from tray 1 1) Vertical paper feed clutch 1 is activated about 30 ms after the paper feed start signal is received, and vertical paper feed roller 4 starts rotating. 2) The internal paper feed unit transfers paper loaded in the paper feed tray unit. 3) The internal paper feed unit stops after paper passes vertical paper feed roller 4, activating vertical paper feed sensor 4. 4) After a specific period once paper has passed vertical paper feed roller 4 and vertical paper feed sensor 4 is activated, the external paper feed motor is started and vertical paper feed roller 5 starts rotating. 5) Vertical paper feed clutch 1 stops after paper passes vertical paper feed roller 5, activating vertical paper feed sensor 5, and vertical paper feed roller 4 stops rotating. Paper feeding from tray 2 1) Vertical paper feed clutch 2 is activated about 30 ms after the paper feed start signal is received, and vertical paper feed roller 2 starts rotating. 2) The internal paper feed unit transfers paper loaded in the paper feed tray unit. 3) The internal paper feed unit stops after paper passes vertical paper feed roller 2, activating vertical paper feed sensor 2. 4) Vertical paper feed clutch 1 starts after a specific period once vertical paper feed sensor 2 is activated, and vertical paper feed roller 3 starts rotating. 5) After a specific period once paper has passed vertical paper feed roller 3 and vertical paper feed sensor 3 is activated, the external paper feed motor is started and vertical paper feed roller 5 starts rotating. 6) Vertical paper feed clutch 1 stops after paper passes vertical paper feed roller 5, activating vertical paper feed sensor 5, and vertical paper feed roller 3 stops rotating. Paper feeding from tray 3 1) Vertical paper feed clutch 2 is activated about 30 ms after the paper feed start signal is received, and vertical paper feed roller 1 starts rotating. 2) The internal paper feed unit transfers paper loaded in the paper feed tray unit. 3) The internal paper feed unit stops after paper passes vertical paper feed roller 1, activating vertical paper feed sensor 1. 4) Vertical paper feed clutch 1 starts after a specific period once vertical paper feed sensor 1 is activated, and vertical paper feed roller 3 starts rotating. 5) After a specific period once paper has passed vertical paper feed roller 3 and vertical paper feed sensor 3 is activated, the external paper feed motor is started and vertical paper feed roller 5 starts rotating. 6) Vertical paper feed clutch 1 stops after paper passes vertical paper feed roller 5, activating vertical paper feed sensor 5, and vertical paper feed roller 3 stops rotating.

Registration rollers Registration sensor

Registration Section: Roller and Sensor Layout

Vertical paper feed roller 5 Vertical paper feed sensor 5

Vertical paper feed roller 4 Vertical paper feed sensor 4

Vertical paper feed roller 3 Vertical paper feed sensor 3

Stripper section Vertical paper feed roller 2 Vertical paper feed sensor 2

Tray 1

Vertical paper feed roller 1 Vertical paper feed sensor 1

Tray 2 Stripper section

Tray 3

Stripper section

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Registration Section Vertical paper feed clutch 2 Vertical paper feed clutch 1 Vertical paper feed sensor 4

Vertical paper feed sensor 3

Vertical paper feed roller 4 Vertical paper feed roller 3 Vertical paper feed sensor 2

Internal paper feed tray 1

Vertical paper feed roller 2 Internal paper feed tray 2 Vertical paper feed sensor 1

Progression of paper

Vertical paper feed roller 1 Internal paper feed tray 3

< REAR View > External paper feed motor Positioning pins

Points of attachment

Vertical paper feed roller 5

1-3. Vertical Paper Feed Unit A Mechanism 1) Paper from the trays (1–3), passing through the internal paper feed and vertical paper feed unit B, is detected by upstream sensors (vertical paper feed sensors 4 and 3). After a specific period, vertical paper feed clutch 2 is activated and vertical paper feed roller 5 receives paper. Vertical paper feed roller 5 is driven by the external paper feed motor. 2) Vertical paper feed clutch 1 is deactivated once paper passes vertical paper feed roller 5 and is detected by vertical paper feed sensor 5. 3) If detection by vertical paper feed sensor 5 occurs after detection of paper jams, the internal and external paper feed motors and electromagnetic clutch are deactivated. (*1) 4) The actual timing of detection as paper passes vertical paper feed sensor 5 is compared to the ideal timing to adjust the transfer speed by vertical paper feed roller 5. This occurs as paper passes the registration sensor and is transferred to the registration roller unit. • If the timing is later than the ideal timing, vertical paper feed roller 5 will increase the rotation speed for faster transfer. • If the timing is sooner than the ideal timing, vertical paper feed roller 5 will decrease the rotation speed for slower transfer. 5) If detection by the registration sensor occurs after detection of paper jams, the internal paper feed motor and electromagnetic clutch will be deactivated. (*1) 6) Once paper reaches the registration rollers, which are stopped, it is transferred until the leading edge is parallel to the registration roller shaft, and the external paper feed motor stops. 7) When paper is transferred by the registration rollers, the vertical paper feed roller 5 rotates 1.03 times faster than the registration rollers to transfer the paper, and when the trailing edge deactivates vertical paper feed sensor 5, the external paper feed motor is stopped. Note 1: Items 3 and 5 describe processing for jam detection.

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Registration Section

Positioning pins (Inserted in unit rear plate) Points of attachment (Affixed to unit front plate with screws)

Drive side guide plate Driven side guide plate

Jam release lever

(Appearance when closed)

Fulcrum

(Appearance when open)

Vertical paper feed sensor 5

Vertical paper feed roller 5

Progression of paper

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Registration Section

1-4. Assist Action Assist control by the vertical paper feed unit is as follows. Assist control by the vertical paper feed section (paper feeding from the internal paper feed tray) serves the following two purposes. 1. To control slippage during paper transfer by the registration roller section, caused by back tension created by stripper pressure from the stripper section and resistance in the paper path. 2. To reduce noise created by flattening paper that has buckled as it is fed in the registration section. Unlike paper feeding from the external paper feed section, paper feeding from the internal paper feed tray may generate significant back tension from stripper pressure in the stripper section and resistance in the paper path. This is due to differences in the layout of the paper path and feed rollers. The back tension may cause slippage when paper is transferred by the registration rollers. Controlling back tension is one purpose of assist control by the vertical paper feed section, in which back tension from the vertical paper feed section is counteracted by running the external paper feed motor in reverse to drive vertical paper feed roller 5. In conjunction with action by the registration rollers, vertical paper feed roller 5 is also operated for assist control. Assist control, which occurs until the trailing edge of sheets leave the vertical paper feed sensor 5, can counteract the effect of back tension occurring in the stripper section or other areas. Assist control is activated in sync with the activation of the registration motor, and the external paper feed motor stops when vertical paper feed sensor 5 is deactivated. Note: By the default setting, the noise reduction is performed in external paper feeding, internal paper feeding, and re-feeding (duplex printing).

External paper feed rollers

Top edge sensor 1 Registration sensor Registration rollers

Vertical paper feed sensor 3

Vertical paper feed sensor 5 Vertical paper feed roller 5

Vertical paper feed roller 3 Vertical paper feed roller 2 Vertical paper feed sensor 2 Vertical paper feed clutch 2

Vertical paper feed clutch 1 Tray 1 Internal paper feed clutch 2 Paper feed roller 2 Tray 2

Force to transfer paper by registration rollers

Force to push against paper by vertical paper feed roller 5 (back tention)

Slippage occurs in registration section paper feeding due to back tention from vertical paper feed section

Tray 1

Tray 2 [ 6-6 ]

ComColor Series (Revision 2.4)

Registration Section

(1)

External paper feed motor ON (Registration motor ON)

(2)

External paper feed motor OFF (Vertical paper feed sensor 5 OFF)

Being transferred

Tray 1

Tray 1

Tray 2

Registration motor External paper feed motor (reversed) Vertical paper feed sensor 5

Tray 2 T ere is also a pattern en t e next s eet is transferred it o t deactivation of sensor

ON OFF ON OFF ON OFF

(2)

(1)

Vertical paper feed sensor 5 OFF

1-5. Registration Roller Mechanism The registration roller section is comprised of the registration rollers (made of rubber), the guide rollers (plastic), the registration sensor, and top edge sensor 1. The registration and guide rollers are constantly subjected to pressure from the guide roller pressure spring. The registration rollers are driven by the registration motor. Registration motor assembly

Registration roller assembly

SS roller assembly

Registration sensor Top edge sensor 1 Guide roller assembly

Part applying pressure

Guide roller pressure spring

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1-6. Paper Position Detection Unit Mechanism This unit is between the registration rollers and the head that is closest to the registration area. The unit is comprised of a section for paper lift/crease detection (including paper retainer), a section for paper width detection, and supporting sections. 1. Detection of Paper Lift • If paper lift exceeds a specific amount, the lift is detected, transfer stops, and operation to clear jamming is executed (by moving the belt platen to the lower limit). • Detection of paper lift Paper lifted higher than a specific amount comes into contact with the detection gate and vibrates. This movement is detected by a sensor and interpreted as lift exceeding the prescribed amount. All types of lift can be detected, including lift at the corners or rippling. 2. Paper Width Detection • Image centering The width of the entire sheet of paper is detected, and images are centered relative to the sheet position. • Masking The paper is constantly detected, and portions of images that exceed the width are masked.

Paper position detection unit Paper lift detection sensor (detection gate) Top edge sensor 2

Suction fan (6 pcs) Transfer belt rollers Transfer belt

Schematic Diagram of Paper Lift Detection

Gate gap Adjustment arm

Top edge sensor 2 (reflective)

CIS

Detection gate

Paper lift detection sensor

Paper Position Detection Unit (Side View)

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Registration Section

Reference for attachment (rear)

Plate spring for correcting torsion

Reference for attachment (front)

Paper Position Detection Unit (Overall View)

Paper Lift Detection Mechanism

Top edge sensor 1

Paper lift detection sensor

Top edge sensor 2

Registration rollers Transfer belt rollers

(1)

Suction fan

Transfer belt

Paper transfer

Paper with a curled leading edge

(2)

(3)

Paper lift detection sensor ON (Lift detected)

Paper lift detection

Transfer stopped (Belt platen stopped)

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Registration Section

1-7. Detection Mechanism for Leading and Trailing Edges (1) Paper Detection Leading and trailing edges are constantly detected by top edge sensors 1 and 2 (incorporated in the head holder). (2) Ink Drop Timing Leading-edge detection data from top edge sensor 2 (reflective), installed just before the head that is most upstream, determines the ink drop timing. If the leading edge cannot be detected by top edge sensor 2(*1), leading-edge data from top edge sensor 1 (transmissive) determines ejection timing. Thus, leading and trailing edges are also constantly detected by top edge sensor 1. *1: Because a reflective sensor is used in top edge sensor 2, the following conditions may cause detection problems. 1. Using preprinted paper that has a printed border. 2. Using colored paper. 3. Using paper with low reflectivity. 4. Duplex printing, in combination with conditions from 1 to 3 of above.

Top edge sensor 1 (send)

Top edge sensor 2 (reflecting type sensor)

CIS

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Registration Section

2. Disassembly 2-1. Vertical Paper Feed Unit A

Vertical paper feed unit A

1. 2. 3. 4. 5. 6. 7.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the center inner cover. (Refer to Chapter 2.) Remove the left inner cover. (Refer to Chapter 2.) Remove the rear cover center assembly. (Refer to Chapter 2.) Put the power supply unit in maintenance position. (Pan-head screw 4x8 (2 pcs)) Remove the belt. Take the wire harness out of the wire saddle.

Timing belt

Reuse band

8. Remove the reuse band. 9. Remove the connector. 10. Remove Vertical paper feed unit A from the front. (IT3C screw 4x8 (2 pcs))

< Vertical Paper Feed Unit A >

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Registration Section

2-2. Vertical Paper Feed Sensor 5 (Vertical Paper Feed Unit A) 1. 2. 3. 4.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit A. (Refer to the instructions for removal.) Remove the sensor cover plate. (W sems screw 3x6 (2 pcs)) Remove vertical paper feed sensor 5. (Sems screw 3x14 (1 pc)) Note: After replacement, check operation by Test Mode No.1031 (vertical paper feed sensor 5).

Sensor cover plate

Vertical paper feed sensor 5

2-3. Vertical Paper Feed Roller 5 (Vertical Paper Feed Unit A) 1. 2. 3. 4. 5. 6.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit A. (Refer to the instructions for removal.) Remove the sensor cover plate. (W sems screw 3x6 (2 pcs)) Remove the gear. (W sems screw 3x8 (1 pc)) Remove the bearings in front and back. (8 mm dia. E-ring (2 pcs)) Remove vertical paper feed roller 5.

Vertical paper feed roller 5

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ComColor Series (Revision 2.4)

Registration Section

2-4. Vertical Paper Feed Unit B 1. 2. 3. 4. 5. 6. 7. 8.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the bottom left-side cover. (Refer to Chapter 2.) Remove the rear cover center assembly. (Refer to Chapter 2.) Remove the left inner cover. (Refer to Chapter 2.) Put the power supply unit in maintenance position. (Pan-head screw 4x8 (2 pcs)) Remove the external paper feed unit. (Refer to Chapter 4.) Remove the connector. (4 pcs) Remove vertical paper feed unit B from the external paper feed section. (IT3C screw 4x8 (4 pcs)) Note: Move the elevator shaft out of the way towards the above while this work.

Vertical Paper Feed unit B

Disconnect wire connectors (4 pcs).

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ComColor Series (Revision 2.4)

Registration Section < Vertical Paper Feed unit B >

Vertical paper feed sensor 4

Vertical paper feed sensor 3

Vertical paper feed sensor 2

Vertical paper feed sensor 1

2-5. Vertical Paper Feed Sensor 1 (Vertical Paper Feed Unit B) 1. 2. 3. 4.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove the sensor bracket for sensor 1. (W sems screw 3x6 (1 pc)) Remove vertical paper feed sensor 1. (Sems screw 3x14 (1 pc)) Note: After replacement, check operation by test mode 1027 (vertical paper feed sensor 1).

2-6. Vertical Paper Feed Sensor 2 (Vertical Paper Feed Unit B) 1. 2. 3. 4.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove the sensor bracket for sensor 2. (W sems screw 3x6 (1 pc)) Remove vertical paper feed sensor 2. (Sems screw 3x14 (1 pc)) Note: After replacement, check operation by test mode 1028 (vertical paper feed sensor 2).

2-7. Vertical Paper Feed Sensor 3 (Vertical Paper Feed Unit B) 1. Turn OFF the machine power and disconnect the power cable from the power source. 2. Remove vertical paper feed unit B. (Refer to the instructions for removal.) 3. Remove vertical paper feed sensor 3 from the plastic tabs. Note: After replacement, check operation by test mode 1029 (vertical paper feed sensor 3).

2-8. Vertical Paper Feed Sensor 4 (Vertical Paper Feed Unit B) 1. 2. 3. 4.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove vertical paper feed sensor 4 with the cover. (P-tight screw 3x8 (2 pcs)) Remove vertical paper feed sensor 4. (Sems screw 3x14 (1 pc)) Note: After replacement, check operation by test mode 1030 (vertical paper feed sensor 4).

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ComColor Series (Revision 2.4)

Registration Section

Pulley Vertical paper feed roller 4

Pulley Pulley

Vertical paper feed roller 3 Vertical paper feed roller 2

Pulley

Vertical paper feed roller 1

2-9. Vertical Paper Feed Roller 1 (Vertical Paper Feed Unit B) 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove pulley assembly S2M30. (6 mm dia. E-ring (2 pcs)) Remove the metal bushing (2 pcs). (6 mm dia. E-ring (2 pcs)) Remove vertical transfer drive roller 1.

2-10. Vertical Paper Feed Roller 2 (Vertical Paper Feed Unit B) 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove pulley assembly 22S3M+30S2M. (6 mm dia. E-ring (2 pcs)) Remove the metal pieces (2 pcs). (6 mm dia. E-ring (2 pcs)) Remove vertical transfer drive roller 2.

2-11. Vertical Paper Feed Roller 3 (Vertical Paper Feed Unit B) 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove pulley assembly S2M30. (6 mm dia. E-ring (2 pcs)) Remove the metal pieces (2 pcs). (6 mm dia. E-ring (2 pcs)) Remove vertical transfer drive roller 3.

2-12. Vertical Paper Feed Roller 4 (Vertical Paper Feed Unit B) 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove pulley assembly 22S3M+30S2M. (6 mm dia. E-ring (2 pcs)) Remove the metal pieces (2 pcs). (6 mm dia. E-ring (2 pcs)) Remove vertical transfer drive roller 4.

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ComColor Series (Revision 2.4)

Registration Section

2-13. Internal Feed Paper Jam Door Interlock Switch (Vertical Paper Feed Unit B) 1. 2. 3. 4. 5. 6.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the external paper feed unit. (Refer to Chapter 4.) Remove vertical paper feed unit B. (Refer to the instructions for removal.) Remove the safety switch spring. Remove the entire switch mounting plate. (3 mm dia. E-ring (1 pc)) Remove the internal feed paper jam door interlock switch. (Sems screw 3x14 (2 pc))

Internal feed paper jam door interlock switch

2-14. Vertical Paper Feed Clutch 1 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the rear cover center assembly. (Refer to Chapter 2.) Put the power supply unit in maintenance position. (Pan-head screw 4x8 (2 pcs)). Remove the vertical paper feed clutch holder. (W sems screw 4x8 (1 pc) and IT3C screw 4x8 (1 pc)). Unplug the wire connector and remove the vertical paper feed clutch 1. Note: After replacement, check operation by test mode 1232 (vertical paper feed clutch 1).

2-15. Vertical Paper Feed Clutch 2 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the rear cover center assembly. (Refer to Chapter 2.) Put the power supply unit in maintenance position. (Pan-head screw 4x8 (2 pcs)) Remove the vertical paper feed clutch holder. (W sems screw 4x8 (1 pc) and IT3C screw 4x8 (1 pc)). Unplug the wire connector and remove the vertical paper feed clutch 2. Note: After replacement, check operation by test mode 1233 (vertical paper feed clutch 2).

< Vertical paper feed clutch holder > Wire connector

Vertical paper feed clutch holder Vertical paper feed clutch 1

Vertical paper feed clutch holder Vertical paper feed clutch 2

< Vertical paper feed clutch >

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ComColor Series (Revision 2.4)

Registration Section

2-16. Registration Motor Assembly 1. 2. 3. 4. 5. 6. 7.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the rear cover center assembly. (Refer to Chapter 2.) Put the engine control PCB in maintenance position. (Pan-head screw 4x8 (2 pcs)) Remove the connector. (2 pcs) Loosen the tensioner. (IT screw 4x8 (2 pcs)) Remove the registration motor assembly. (IT3C screw 4x8 (4 pcs)) Remove the mounting bracket. (W sems screw 4x8 (4 pcs)) Note: Remember to reattach the belt. Note: After replacement, check the operation by test mode 1226 (registration motor).

Registration motor Engine control PCB

Registration motor

Tensioner

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ComColor Series (Revision 2.4)

Registration Section

2-17. Registration Sensor (Send) 1. 2. 3. 4.

Turn OFF the machine power and disconnect the power cable from the power source. Open vertical paper feed unit A. Unhook the plastic hook of the sensor cover from the sensor bracket, and then unhook the relay connector. Remove the registration sensor (send). Note: After replacement, check the sensor operation by test mode 1025 (registration sensor).

2-18. Registration Sensor (Receive) 1. Turn OFF the machine power and disconnect the power cable from the power source. 2. Unhook the plastic hook of the sensor cover from the guide plate, and then unhook the relay connector. 3. Remove the registration sensor (receive). Note: After replacement, check the sensor operation by test mode 1025 (registration sensor).

Registration roller

Registration sensor (receive)

Guide roller

Registration sensor (send)

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ComColor Series (Revision 2.4)

Registration Section

2-19. Top Edge Sensor 1 (Send) 1. Turn OFF the machine power and disconnect the power cable from the power source. 2. Unhook the plastic hook of the sensor cover from the mounting bracket, and then unhook the relay connector. 3. Remove top edge sensor 1 (send). Note: After replacement, check the sensor operation by test mode 1102 (top edge sensor 1).

2-20. Top Edge Sensor 1 (Receive) 1. Turn OFF the machine power and disconnect the power cable from the power source. 2. Unhook the plastic hook of the sensor cover from the guide plate, and then unhook the relay connector. 3. Remove top edge sensor 1 (receive). Note: After replacement, check the sensor operation by test mode 1102 (top edge sensor 1).

Registration roller

Top edge sensor 1 (receive) Guide roller

Top edge sensor 1 (send)

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ComColor Series (Revision 2.4)

Registration Section

2-21. Registration Roller 1. 2. 3. 4. 5. 6. 7. 8. 9.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the center inner cover. (Refer to Chapter 2.) Remove the left inner cover. (Refer to Chapter 2.) Remove the rear cover center assembly. (Refer to Chapter 2.) Remove the left top cover. (Refer to Chapter 2.) Put the engine control PCB in maintenance position. (Pan-heads screw 4x8 (2 pcs)) Remove the front door lock mechanism. (IT3C screw 4x8 (4 pcs)) Manually slide the Ink pan away from the BP Unit and remove the Guide roller pressure spring. Set a 7.0mm wrench on the front end of the Registration roller shaft to prevent the shaft from rotating. (Hook the wrench in the double-D cut section on the registration roller shaft in the front as shown on the photo.) 10. Remove the screw with a large washer from the center of the Registration shaft on the rear of the machine. (3x6 screw with built-in large washer.) 11. Remove the bearing from the front of the Registration roller shaft after removing a bearing stopper screw (Panhead screw 3x6 (1 pc) and a white plastic collar (1 pc)). < Pay caution not to drop the plastic collar. > There is no need to remove the bearing from the rear end of the Registration roller shaft. 12. Slide the Registration roller forward to disengage the the drive gear in back, and then remove it from the front.

< View from the FRONT > - the Ink Pan is manually moved away from the BP Unit, which is at the lower limit position Guide roller pressure spring

< FRONT of the machine > < REAR of the machine >

Registration motor 7 mm Wrench

DO NOT REMOVE

REMOVE Watch for the Collar.

Remove the Screw

BEARING to be removed

Screw with a large washer Registration roller shaft

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ComColor Series (Revision 2.4)

Registration Section

2-22. Guide Roller Note: Be careful not to touch print heads during this work. Turn OFF the machine power and disconnect the power cable from the power source. Remove the center inner cover. (Refer to Chapter 2.) Remove the left inner cover. (Refer to Chapter 2.) Remove the left top cover. (Refer to Chapter 2.) Put the Engine control PCB in maintenance position. (Pan-head screw 4x8 (2 pcs)) Manually slide the Ink pan away from the BP Unit and remove the Guide roller pressure spring. Remove the guide roller unit. (8 mm dia. E-ring in front and back (1 pc each)) Note: Slide the Guide roller unit forward to take out the fulcrum shaft from the metal bushing in the back, and then remove it from the front. 8. Remove the plastic clip from the Guide roller shaft and remove the Guide roller from the unit. 1. 2. 3. 4. 5. 6. 7.

Guide roller assembly

E-Ring E-Ring

< REAR View >

< FRONT View > Guide roller assembly

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ComColor Series (Revision 2.4)

Registration Section

2-23. Paper Position Detection Unit 1. 2. 3. 4. 5. 6. 7. 8.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the center inner cover. (Refer to Chapter 2.) Remove the left inner cover. (Refer to Chapter 2.) Remove the rear cover center assembly. (Refer to Chapter 2.) Put the engine control PCB in maintenance position. (Pan-head screw 4x8 (2 pcs)) Remove the front door lock mechanism. (Pan-head screw 4x8 (4 pcs)) Unplug the wire harness connector. (3 pin connector in front and 14 pin connector in the back.) Remove the paper position detection unit from the front. (Pan-head screw 4x8 (1 pc)) Note: Adjustment of the gate height may lead to damaging of the Print Heads. Do not adjust the gate. Note: Use of the alcohol to clean the CIS glass is not recommended.

Connector

Paper position detection unit SCREW

Front door lock mechanism

Paper position detection unit

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ComColor Series (Revision 2.4)

Registration Section

2-24. Paper Lift Detection Sensor 1. 2. 3. 4. 5.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the paper position detection unit. (Refer to the instructions for removal.) Remove the paper lift detection sensor assembly. (W sems screw 3x6 (1 pc)) Remove the sensor cover. (Bind screw 3x6 (1 pc)) Remove the paper lift detection sensor. Note: After the sensor replacement, check the sensor operation by test mode 1104 (paper lift detection sensor).

Paper position detection unit

Paper lift detection sensor assembly Paper lift detection sensor

2-25. Paper Width Detection Sensor (FRONT & REAR) 1. 2. 3. 4. 5. 6.

Turn OFF the machine power and disconnect the power cable from the power source. Remove the Paper position detection unit. (Refer to the instructions for removal.) Remove the CIS mounting assembly. (W sems screw 3x6 (2 pcs)) Unplug the connectors. Remove the CIS retaining plates (4 pcs). (P-tight screw 3x8 (1 pc each)) Remove the front and rear paper width detection sensors. Note: Do not use alcohol in cleaning the CIS glass.. CIS mounting assembly

Paper Width Detection Sensor (FRONT)

Paper Width Detection Sensor (REAR)

CIS retaining plates

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Registration Section

MEMO

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ComColor Series (Revision 2.4)

Registration Section

3. Adjustment 3-1. Adjustment to Make the Registration Roller and BP Unit Parallel Adjust the alignment of the registration roller after replacing the registration roller or registration roller unit. Refer to Chapter 11, Section 3, "Adjustment: Adjusting the Registration Roller."

3-2. CIS Adjustment Instructions for adjusting the CIS and checking the adjustment are as follows. This adjustment is to correct uneven lighting from the CIS light source (shading compensation). Here, a sheet of clean white paper exceeding the maximum paper feed supported width of 340 mm (A3 or Ledger size paper cut to the length of 360 mm and laid sideways on the BP unit is good) is scanned and stored as the reference white value. Do this after replacing the CIS or paper position detection unit. Although the front and rear units are generally adjusted at the same time, they can also be adjusted individually. ComColor models 9110, 7110 and 3110 contain only one CIS unit on the rear of the machine, which is the left hand-side of the printed papers. On these three models, only the rear CIS is adjusted --- the right-hand-side edge of the paper on these machine models are calculated from the data scanned by the CIS on the rear of the machine and the paper size information received from the paper feed tray.

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A3 or Ledger size paper cut to the length of 360 mm and laid sideways on the BP Unit.

Paper corner reference position.

Approx. 360 mm

1. Adjustment Procedure 1) Execute test mode 2407 (move the BP elevation motor to the lower limit position). 2) Open the right front cover. 3) Place a piece of paper on top of the BP Unit in the machine with the corner of the paper set at the position shown on the photograph. > Loading Position 1: < When adjusting both CIS units at the same time.> Place a piece of paper cut to the length shown below (approx. 360 mm) on top of the BP Unit in the machine with the corner of the paper set at the position shown on the photograph below.

ComColor Series (Revision 2.4)

Registration Section > Loading Position 2: < When adjusting only the rear (left-side) CIS.> Place an A4 size sheet (297 mm) sideways in the position shown on the photograph below left. Confirm that the outside edge of the black plastic plate on the BP Unit in the front is approximately 70 mm from the edge of the A4 size paper placed on the BP Unit.

297 mm

REAR

A4 size paper

70 mm

Paper corner reference position.

FRONT

Loading Position 3: < When adjusting the front (right-side) CIS.> Place an A4 sheet, as shown, on the following photograph with the paper corner aligned at Loading Position 1,shown on the previous page.

REAR

A4 size paper

FRONT CAUTION: Confirm that the BP registration pin hole is not covered by the paper.

FRONT

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ComColor Series (Revision 2.4)

Registration Section 4) Close the right front cover. 5) Execute the following CIS shading compensation test modes, depending on the paper loading position. Loading Position 1: Test Mode 2461 (shading compensation for the left and right CIS at same time) Loading Position 2: Test Mode 2462 (shading compensation for the left CIS only) Loading Position 3: Test Mode 2463 (shading compensation for the right CIS only) Note: Execute only the Test Mode 2462 for machines with only the left CIS, such as ComColor models 9110, 7110 and 3110. < Error Displays > 1. This process ends with an error if the CIS reference voltage was not read correctly. (See Note 1 on next page.) • W58-0225-1: Incorrect reference voltage for the left CIS • W58-0225-2: Incorrect reference voltage for the right CIS • W58-0225-3: Incorrect reference voltage for the left and right CIS 2. This process ends with an error if the unit determines that paper was not loaded in the specified position. (See Note 1 on next page.) • W58-0226-1: Reference paper loading error for shading compensation of the left CIS • W58-0226-2: Reference paper loading error for shading compensation of the right CIS • W58-0226-3: Reference paper loading error for shading compensation of the left and right CIS • W58-0226-4: No reference paper loaded for CIS shading compensation 3. This process ends with an error if shading compensation not executed correctly. (See Note 1 on next page.) • W58-0227-1: Shading compensation error for the left CIS • W58-0227-2: Shading compensation error for the right CIS • W58-0227-3: Shading compensation error for the left and right CIS 6) Open the right front cover. 7) Remove the paper. 8) If you have executed shading compensation for the left and right CIS, go to step 2, "Confirmation Procedure." If you have only adjusted one side, return to step 1 and adjust the other CIS. 2. Confirmation Procedure 1) Load a sheet of lightweight Riso paper on the transfer belt. (Load an A4 sheet in portrait orientation, where it can be detected by the CIS.) Note: • Load the sheet centered relative to the width of the transfer belt. • Load the sheet parallel relative to the transfer direction of the transfer belt. (Use the suction holes of the transfer belt for reference.) 2) Close the right front cover. 3) Execute test mode 2464 (checking CIS action). 1. This process ends with an error if the CIS reference voltage was not read correctly. (See Note 2 on next page.) • W58-0225-1: Incorrect reference voltage for the left CIS • W58-0225-2: Incorrect reference voltage for the right CIS • W58-0225-3: Incorrect reference voltage for the left and right CIS

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ComColor Series (Revision 2.4)

Registration Section 2. An error occurs if paper is not detected. (See Note 2 on this page.) • W59-0228-1: Edge detection error when confirming action of the left CIS • W59-0228-2: Edge detection error when confirming action of the right CIS • W59-0228-3: Edge detection error when confirming action of the left and right CIS 4) Open the right front cover. 5) Remove the paper. 6) Close the right front cover. 7) Execute the following test modes and check the value of each. 1. Execute test mode 1609 (left CIS paper level detection results). 2. Execute test mode 1610 (right CIS paper level detection results). Note: No need to execute Test Mode No.1610 for machines without the right CIS. Description: Indicates the paper level (as a percentage, with the reference paper level as 100%) when test mode 2464 (checking CIS action) was executed. Criteria: Acceptable if in the range 95–105%. 3. Execute test mode 1611 (left CIS belt level detection results). 4. Execute test mode 1612 (right CIS belt level detection results). Note: No need to execute Test Mode 1612 for machines without the right CIS. Description: Indicates the belt level (as a percentage, with the reference belt level as 100%) when test mode 2464 (checking CIS action) was executed. Criteria: Acceptable if 25% or less. 8) Execute test mode 1608 (CIS paper width detection results). Description: Indicates the paper width (in 0.1 mm increments) when test mode 2464 (checking CIS action) was executed. Criteria: Acceptable if in the range 2090 to 2110 when A4 paper in portrait orientation was loaded. Note:No need to execute Test Mode No.1608 for machines with only the left CIS, such as ComColor models 9110, 7110 and 3110. 9) If any item is unacceptable, repeat the adjustment procedure. 10) When all items are acceptable, execute test mode 1497 (save adjustment values). This backs up the settings values, which can be accessed by executing test mode 0503 (factory defaults). Note 1: Adjustment ends with an error in the case of errors W58-0225 to 0227 and default settings are restored (reference paper level: 0, threshold: 0, offset value: 128 (0 mV), black and white adjustment data: All 0). In this case, CIS-based masking (edge detection) is not performed. Note 2: Confirmation ends with an error in the case of errors W58-0225 and W59-0228, but the default settings as described in note 1 are not restored. < Determination of Errors > 1. Incorrect CIS reference voltage (W58-0225) Criteria: If the reference voltage was not read correctly during the adjustment when the CIS was activated, it is interpreted as a reference voltage error. Under the worst-case conditions, this error may occur when the reference voltage is 400 mV or less or 1,280 mV or more. Countermeasure: 1. Confirm the CIS is correctly connected. (Check the connection of connectors, for example.) 2. Replace the CIS. 3. Replace the Image Processing PCB.

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ComColor Series (Revision 2.4)

Registration Section 2. No reference paper during shading compensation (W58-0226-4) Criteria: If the average maximum value of five measurements outside the CIS masking area (the area 400 pixels from the left and right edges) after black adjustment is 6,600 or less, it is interpreted as a lack of reference paper. Countermeasure: Load proper reference paper. 3. Reference paper loading error during shading compensation (W58-0226-1, 2, 3) Criteria: If the average minimum value of five measurements outside the CIS masking area (the area 400 pixelsfrom the left and right edges) after black adjustment is 50% of the maximum value or less, it is interpreted as loading reference paper outside the specified position. Countermeasure: 1. Making sure that the reference paper is clean, place it in the correct position. 2. Confirm that the CIS surface is clean. 4. Shading compensation error (W58-0227) Criteria: Regarding the average value of five measurements after shading compensation, if the maximum value minus the minimum value divided by the reference paper level is 0.05 or more, it is interpreted as a compensation error. This enables you to confirm that shading compensation within 5% was executed. Countermeasure: Repeat the adjustment procedure. 5. Edge detection error when checking CIS action (W59-0228) Criteria: The paper edge cannot be detected. Countermeasure: Try replacing the paper.

3-3. Sensor Sensitivity Adjustment The sensor sensitivity needs to be adjusted when the Registration sensor, Top edge sensor 1 or Top edge sensor 2 is replaced. 1. Registration sensor & Top edge sensor 1 Make following adjustment when either of these two sensors are replaced. 1) Place either A3 (Ledger) or A4 (Letter) size clean white paper of which the customer normally uses, on the external paper feed tray. 2) Press the tray elevation button or execute test mode No.1423 to raise the external paper feed tray to the upper limit position. 3) Execute test mode No.1498 to automatically feed the paper to the two sensors. 4) Execute test mode No.1494 to automatically adjust the sensitivity of the two sensors. Note: The two sensors, Registration sensor and Top edge sensor 1, are both adjusted at the same time. 5) Remove the paper from the machine. The above sequence are described on the next page by an illustration.

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ComColor Series (Revision 2.4)

Registration Section [Registration sensor] & [Top edge sensor 1] sensitivity adjustment sequence:

Registration sensor (receive)

Top edge sensor 1 (receive)

Transfer belt

Registration sensor (send)

1)

Registration roller

Top edge sensor 1 (send)

Place a white sheet paper, which the customer uses the most, on the external paper feed tray. and raise the tray.

Paper

2)

Execute test mode No.1498 to automatically feed the paper. Paper starts to feed. Make sure that the paper is not curled or lifted.

3)

Test mode No.1498 completed. The paper stops after going past the Top edge sensor 1.

4)

Execute test mode No.1494 to automatically adjust the sensitivity of the Registration sensor and Top edge sensor 1.

5)

Remove the paper from the machine to complete the adjustment.

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ComColor Series (Revision 2.4)

Registration Section 2. Top edge sensor 2 (reflecting type sensor) Make following adjustment when the Tope edge sensor 2 is replaced. 1) Confirm that the BP unit is all the up to the printing position. If not, activate test mode No.2405 to raise the BP unit to the upper limit position (printing position). 2) Activate test mode No.1495 to automatically adjust the sensor sensitivity. When the test mode is activated, the PB motor and PB Fan goes ON and the Top edge sensor 2 activates to make sensitivity self adjustment. The sensitivity adjustment is made against the black color of the BP Transfer belt, so no paper is need for this adjustment.

Top edge sensor 2 (reflective type sensor) Drive roller Driven roller

1)

If the BP unit is not all the way up in the printing position, use test mode No.2405 to raise the BP unit. Make sure that there is no paper on the external paper feed tray.

2)

With the execution of test mode No.1495, the BP belt rotates and the BP Suction fan activates.

3)

The Top edge sensor 2 automatically does the sensitivity adjustment.

4)

The BP belt stops, BP suction fan deactivates and ends the adjustment.

BP suction fan

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Transfer belt

ComColor Series (Revision 2.4)

Registration Section

MEMO

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ComColor Series (Revision 2.4)