Fresa G024 Service Manual Download Page 1

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FRESA (G024)

SERVICE MANUAL

[Engine]

Summary of Contents for G024

Page 1: ...FRESA G024 SERVICE MANUAL Engine...

Page 2: ...n 6 The interior and metal parts for the fusing unit become extremely hot while the printer is operating Do NOT touch these components with bare hands HEALTH SAFETY CONDITIONS 1 Never operate the prin...

Page 3: ...r chassis is not field repairable Customer engineers are therefore directed to return all chassis and laser subsystems to the factory or service depot when the optical subsystem requires replacement W...

Page 4: ...are registered trademarks of Apple Computer Inc NetWare is a registered trademark of Novell Inc Ethernet is a registered trademark of Xerox Corporation General Notice Other product names used herein a...

Page 5: ...o 297 mm Specify the paper size with the system menu at the operation panel by the user Paper Weight Standard and optional trays 64 to 105 g m2 17 to 28 lbs By pass feed tray 64 to 157 g m2 17 to 42 l...

Page 6: ...W Energy saver mode Less than 45 W Noise Emission Sound Power Level Stand by Less than 43 dB Operating Less than 64 dB without paper tray unit Less than 66 dB with paper tray unit Dimensions 660 x 62...

Page 7: ...GE FORMATION PROCESS OVERVIEW 1 OPC belt 2 Charge 3 Exposure 4 Development 5 Transfer belt 6 Transfer belt cleaning 7 Paper separation 8 Paper transfer secondary transfer 9 Belt transfer primary trans...

Page 8: ...r than the development bias In this machine monocomponent toner is used there is no carrier In black single color mode 1C the image is developed in K only In full color mode 4C the image is developed...

Page 9: ...plies lubricant to the OPC belt to improve cleaning Then a blade scrapes off the remaining toner on the OPC belt 12 Quenching After cleaning the entire surface of the OPC belt is exposed to light from...

Page 10: ...s form a full color image on the transfer belt then the image is finally transferred to the paper G024V670 WMF Forming a visual image on the OPC belt Transferring the image onto the transfer belt Turn...

Page 11: ...e charge corona wire receives a constant current C of 700 A about 5000 V The charge grid voltage G varies depending on the process control results Range 320 V to 820 V Default 600 V G024V662 WMF OPC b...

Page 12: ...bed below SB supply roller bias Default 348 V Range 218 V to 468 V BL development blade bias This is always SB 132 V If SB changes so does BL Default 480 V 180 Vac is always super imposed over this vo...

Page 13: ...er roller at about 1 8 kV to attract the toner from the transfer belt The machine adjusts the transfer current automatically for variations in temperature humidity paper size and paper thickness After...

Page 14: ...ptical housing unit 2 Main control unit MCU 3 High voltage supply unit 4 Controller board 5 Power supply unit 6 Fusing unit 7 Paper transfer unit 8 Photoconductor unit PCU 9 Paper tray paper feed mech...

Page 15: ...tputs 5 VDC 24 VDC 120 230 VAC 6 Fusing unit Fusing method Hot roller method Oil application Application roller method Cleaning Cleaning roller method Temperature detection Thermistor Safety precautio...

Page 16: ...it 8 Controller board 9 Power supply unit 10 Exit rollers 11 Hot roller 12 Pressure roller 13 Transfer belt cleaning unit 14 Transport fan 15 Paper transfer unit 16 Transfer belt 17 Registration rolle...

Page 17: ...ve gear 4 Transfer belt toner collection drive gear 5 Transfer roller clutch 6 Registration clutch 7 By pass feed clutch 8 Relay roller clutch 9 Pull out clutch 10 Paper feed clutch 11 Paper feed driv...

Page 18: ...PARTS LAYOUT 31 March 1999 1 14 1 PCU pulley 2 PCU motor 3 OPC drive relay gear 4 OPC drive gear G024V563 WMF 1 2 3 4...

Page 19: ...sensor 4 Transfer roller position sensor 5 Used toner sensor 6 PCU reset sensor 7 Paper end sensor 8 ID sensor 9 Pull out sensor 10 By pass paper end sensor 11 Registration sensor 12 Toner end sensor...

Page 20: ...999 1 16 1 4 4 SWITCHES 1 Main switch 2 Exit cover switch 3 Door safety switches 4 Paper size switch 5 PCU set switch 6 Charge corona unit set switch 7 Development toner magazine DTM cover switch G024...

Page 21: ...4 Main motor 5 Revolver motor 6 Polygon mirror motor 7 Development drive solenoid 8 Pull out clutch 9 Paper feed clutch 10 Relay roller clutch 11 By pass feed clutch 12 Registration clutch 13 Transfe...

Page 22: ...SU 2 Controller board 3 High voltage supply board 4 Temperature humidity sensor 5 Main control unit MCU 6 Laser synchronization detector board 7 Quenching lamp 8 By pass paper width detection board 9...

Page 23: ...9 Overall Information 1 4 7 THERMISTORS HEATERS AND FUSES 1 Pressure roller thermistor 2 Pressure roller lamp 3 Hot roller thermofuse 4 Hot roller thermistor 5 Hot roller lamp 6 Pressure roller thermo...

Page 24: ...Generation Motor Control Video I F GAVD PLLC High Voltage Supply Board ADC P W M Fusing Control Fusing Unit Solenoids Clutches LD Modulation Control Printer Controller Revolver Main Motor PCU Motor A...

Page 25: ...paper tray 9 S10 By pass paper end sensor Detects paper in the by pass tray 10 S15 Registration sensor Detects paper at the registration roller 11 S12 Toner end sensor Detects whether there is toner...

Page 26: ...CHES Symbol Name Function Diag No CL5 Pull out clutch Controls the pull out roller drive 8 CL2 Paper feed clutch Controls the first tray paper feed roller drive 9 CL3 Relay roller clutch Controls the...

Page 27: ...olygon mirror 6 L3 Quenching lamp Quenches the OPC by exposing it to light 7 PCB6 By pass paper width detection board Detects the paper width in the by pass feeder 8 PCB5 Laser diode LD unit Controls...

Page 28: ...as VB This is adjusted to maintain a consistent image density in solid areas Charge corona grid voltage VG This is adjusted to maintain a constant image density in low image density highlight areas To...

Page 29: ...is because black toner is blocking the reflection of light back into the sensor from the transfer belt the transfer belt itself is black but it is reflective However the diffused light sensor output...

Page 30: ...mode or an equivalent number of sheets in another mode have been printed upon completion of a job The interval can be changed with engine SP 7 Process Control Interval Set c f g h Power on When the f...

Page 31: ...ut of a maximum of 255 The ID sensor detects the density of this pattern Based on the result the development bias for black is adjusted to obtain a M A of 0 58 mg cm2 on the transfer belt for areas of...

Page 32: ...cess control see the table two pages ago Because of this the solid area density based on the VB obtained during initialization may change as a result of changes inside the machine after a period of us...

Page 33: ...t drive roller 5 Charge corona unit 6 OPC belt cleaning blade 7 Quenching lamp 8 Used toner tank 9 Transfer belt idle roller 10 OPC belt toner collection auger 11 OPC belt lubricant bar 12 OPC belt cl...

Page 34: ...lows air into the charge corona unit to disperse ozone Transfer belt The toner image on the OPC belt is transferred onto the transfer belt Later it will be transferred to the paper from the belt Trans...

Page 35: ...ive roller C via gears and two joints D The OPC E and transfer F belts rotate at the same speed The two joints for the transfer belt G and the OPC H engage when the front cover I is closed When the fr...

Page 36: ...ction auger E and used toner collection auger F via a series of gears Transfer belt revolutions The transfer belt has 15 marks on it at 39 2 mm intervals one full rotation of the transfer belt is 588...

Page 37: ...printing on transparencies or on thick paper the paper transfer and fusing unit speeds slow to 1 2 speed to improve paper transfer and fusing Single color black mode K When four transfer belt marks h...

Page 38: ...E SUPPLY The high voltage board A supplies the belt transfer voltage to the PCU through the connector B then the coil spring electrode C and finally the bias roller D to the transfer belt E Opening th...

Page 39: ...harge inlet fan C removes ozone from the charge corona unit The charge corona unit has a sliding cleaner D so that the user can clean the wire and grid The high voltage board applies a constant curren...

Page 40: ...leaning brush C lubricates the OPC belt with zinc stearate by using a spring to apply pressure to the lubricant bar D A cleaning blade E scrapes the OPC belt to remove the remaining toner The OPC belt...

Page 41: ...pplied to the transfer belt bias roller A The default is 800 V It changes according to environmental conditions temperature and humidity measured by the sensors The bias pulls the toner from the OPC b...

Page 42: ...ide directs the toner into the OPC toner collection area In 4C mode the cleaning unit separates from the transfer belt after the first image Y has been formed and stays away from the belt while the C...

Page 43: ...spring under tension in the shutter cover pulls and closes the shutter The toner collection auger inside the tank transports the toner falling into the used toner tank preventing the toner from accum...

Page 44: ...r tank is absent the PCU detects that it is missing 2 2 10 CHARGE CORONA UNIT DETECTION The main unit has a switch A to detect the presence of a charge corona unit If the charge corona unit B is insta...

Page 45: ...nsfer belt moves forward one mark Laser exposure in the sub scan direction for the next page starts there Because the PCU motor drives the transfer and OPC belts at the same time this prevents repeate...

Page 46: ...belt is also lubricated at this time However the transfer belt requires more lubrication than the OPC belt Therefore step 2 is done to lubricate the transfer belt without applying toner to the OPC Thi...

Page 47: ...the process control interval run out at the same time process control is done first Counting method Color 4 counts print Monochrome 1 count print The lubrication interval A in the flow chart can be a...

Page 48: ...7 F theta Mirror 8 BTL Barrel Torroidal Lens 9 Laser Synchronization Mirror 10 Laser Synchronization Detector Board 11 Dust Shield Glass The optical unit uses a six sided polygon mirror that turns at...

Page 49: ...ving six sided mirror Polygon mirror motor Turns the mirror at 23 922 rpm F theta mirror Compensates for dot position irregularities in the main scan direction BTL Compensates for leaning faces Mirror...

Page 50: ...safety switch shuts off the 5V DC line to the LD unit LD unit configuration The LD unit consists of a laser diode LD A collimating lens B aperture C and LD control board D The collimating lens focuses...

Page 51: ...he sub scan direction Polygon mirror The polygon mirror A is a combined unit consisting of a polygon mirror motor and a mirror The polygon mirror is six sided The mirror surfaces are precisely ground...

Page 52: ...weeping across the belt more quickly The F theta mirror B compensates for the differences in the distance to ensure an equal gap between pixels BTL Barrel Torroidal Lens Irregularities in the perpendi...

Page 53: ...board responses are sent to the MCU laser exposure controller as synchronization signals for LD exposure start position across the main scan Synchronization detection error If a synchronization detect...

Page 54: ...LD When the current exceeds 133 mA DC the LD control panel issues an error detection signal to the MCU SC 42 code is displayed 2 3 5 LASER EXPOSURE CONTROL Laser exposure control enables an equivalen...

Page 55: ...int the CPU waits for a certain number of clock cycles Then the first time that MARK goes high after this FGATE goes high after a certain number of PMSYNC signals LGATE is generated from LSYNC laser m...

Page 56: ...ar 3 Hopper 4 Development roller The development unit consists of independent Y C M and K units known as development toner magazines or DTMs combined with a support unit The development unit rotates c...

Page 57: ...The DTM set sensor detects the presence of a DTM Toner supply Toner end sensor The toner end sensor detects the presence of toner Toner supply The supply roller supplies toner to the development roll...

Page 58: ...s this protrusion The revolver turns 45 degrees and stops for Y color development then turns 90 degrees for C color development then another 90 degrees for M color development Then the revolver turns...

Page 59: ...2 2 4 4 DEVELOPMENT UNIT DRIVE Gears and joints A transfer drive from the main motor B to the gears for the supply C and development D rollers The joint only engages while the development drive soleno...

Page 60: ...tates the toner inside the hopper When the hopper is at the top the toner is at the supply port A for the development roller When the hopper turns towards the bottom the toner falls from the toner sup...

Page 61: ...y roller Then the rotation of the supply roller D transports the toner to the development roller C The development blade E forms an even layer of toner to a specified thickness on the development roll...

Page 62: ...is connected only while development is in progress When development for one color finishes the bias transfers to the next color G024D166 WMF G024D165 WMF Development roller bias Supply roller bias Bla...

Page 63: ...The DTM sensor outputs an error detection signal when a toner bottle is not present or is incorrectly installed Printing cannot start until this signal ceases i e the error must be corrected Installi...

Page 64: ...cleaner D swings across to clean the mirror surfaces when the revolver turns If there is sufficient toner the light path is blocked When light passes through the sensor for the first time the machine...

Page 65: ...March 1999 2 38 2 4 10 DEVELOPMENT TIMING LT long edge feed two image print mode Belt mark Laser exposure Revolver Development solenoid Development bias Belt transfer bias Change over Change over Y C...

Page 66: ...IEW 1 Transfer roller casing 2 Transfer roller springs 3 Transfer roller 4 Antistatic brush 5 Transfer roller position sensor 6 Transfer roller clutch The paper transfer unit moves into contact and se...

Page 67: ...nst the transfer belt Transfer roller clutch Moves the paper transfer unit into contact and away from the transfer belt Contact separation Transfer roller position sensor Detects whether the paper tra...

Page 68: ...transfer roller is driven by contact with the transfer belt If the transfer roller contacts the transfer belt i e the transfer roller position sensor is on just after the main switch is turned on or j...

Page 69: ...er clears a paper jam or closes the front cover the transfer roller turns and positive and negative currents are alternately applied This removes any toner that got stuck to the transfer roller during...

Page 70: ...switch 3 Tray paper feed roller 4 Tray paper end sensor 5 Pull out sensor 6 Pull out rollers 7 Relay rollers 8 By pass feed table 9 By pass paper width detection board 10 By pass pick up roller 11 By...

Page 71: ...by a feeler and photo interrupter Paper tray Paper size detection User specified by a dial detected by switches Paper feed separation FRR method Paper end detection Detection by a feeler and photo in...

Page 72: ...rom the main motor is transferred from the timing belt to the paper feed drive gear A The paper feed drive gear drives the paper feed roller and pull out roller via gears These two rollers each have a...

Page 73: ...the separated sheet to the relay rollers which then feed the sheet to the registration roller When the registration sensor detects the sheet the machine feeds the paper another 28 mm then the relay ro...

Page 74: ...he paper tray to the paper tray arm C When the paper tray is placed in the main unit the guide block D for the main unit base lifts the paper tray arm The springs keep the top of the paper stack at th...

Page 75: ...h 1999 2 48 Paper end detection The paper end sensor A is on the floor of the main unit When there is no paper in the paper tray the sensor actuator B falls into the notch in the bottom plate causing...

Page 76: ...e side facing the paper size switches Each switch turns off when it falls into a groove and turns on when a ridge presses it Paper size detection for tray 1 Sensor Status Dial No Paper Size XNOB2 XNOB...

Page 77: ...rive change over between the paper feed roller D and the pick up roller E When the clutch is on the pick up roller turns when the clutch is off the feed roller turns The revolution of the separation r...

Page 78: ...y clutch inside the paper feed roller D prevents reverse revolution The separation roller turns in the opposite direction to the paper feed roller The separation roller axle has a torque limiter made...

Page 79: ...detection for the by pass feed tray Sensor Status Paper Size XBIT0 XBIT1 XBIT2 XBIT3 A4 LEF 1 1 0 0 A3 SEF 1 1 0 0 81 2 x 11 LEF 1 1 0 0 11 x 17 SEF 1 1 0 0 71 4 x 101 2 LEF 1 1 0 1 B5 JIS LEF 1 1 0...

Page 80: ...relay roller clutch disengages pausing the paper feed The relay roller clutch B and registration clutch C engage simultaneously to restart paper feeding at the correct time to synchronize with the lea...

Page 81: ...ssure adjustment screw 4 Exit rollers 5 Oil bottle 6 Hot roller cleaning roller 7 Oil supply roller 8 Oil reservoir 9 Oil supply pad 10 Oil supply sub roller 11 Oil blade 12 Hot roller 13 Fusing lamp...

Page 82: ...pressure from a lever and screw mechanism Oil supply The oil supply pad absorbs oil The oil supply roller applies a very small amount of oil to the hot roller via the oil supply sub roller The blade e...

Page 83: ...lever C in direction D This lifts the fusing contact separation gear which engages with the fusing drive gear E Opening the front cover lowers the fusing contact separation gear disengaging the gear t...

Page 84: ...e guide plate below the entrance to the fusing unit The transport fan turns on when the paper has been fed 101 89 mm since the registration clutch turned on The transport fan is turned off one second...

Page 85: ...e within this cycle the printer may switch the lamp on for 0 6 s and off for 0 4 s In level 1 energy saving mode the fusing lamps are turned off In level 2 energy saving mode the fusing lamps are inte...

Page 86: ...passed after the main motor halted Then the roller temperature has been below 130 C for 60 seconds 49 Pressure roller reheat timeout When reheating the roller temperature does not reach the reheat st...

Page 87: ...ller B is made of silicone covered with Teflon tubing A compressed spring and a screw C press the pressure roller against the hot roller NOTE Do not turn the pressure screw except for nip width adjust...

Page 88: ...the LED passes through to the phototransistor However if oil is present the beam from the LED is refracted away and does not reach the phototransistor When oil is not detected continuously for 10 sec...

Page 89: ...he oil is absorbed in the oil supply pad C fed to the oil supply roller D by the oil supply sub roller E and supplied to the hot roller F NOTE When an oil bottle is replaced with oil still in it oil m...

Page 90: ...toner or paper dust from the hot roller and the scraper C removes them from the cleaning roller The dust drops into the recess D behind the scraper 2 7 10 PAPER EXIT COVER OPEN CLOSED DETECTION The pa...

Page 91: ...tically moves the lever in contact with the actuators for the door safety switches B The actuators turn the 5 VDC and 24 VDC power lines on and off 2 8 2 DTM COVER OPEN CLOSED DETECTION A switch that...

Page 92: ...in the case of 8 bit RGB data the controller has to convert this to 8 bit CMYK data before image processing can start Then gamma compensation corrects the CMYK data a combination of the controller ga...

Page 93: ...h a range of pixels above and to the left and is converted to an 8 bit value based on the results using an internal look up table The data then passes to the GAVD Gate Array Video interface through th...

Page 94: ...ubjected to sudden temperature changes b where it will be directly exposed to cool air from an air conditioner c where it will be directly exposed to heat from a heater 5 Do not place the machine wher...

Page 95: ...ithin 5 mm 0 2 of level 2 Right to left Within 5 mm 0 2 of level 3 3 MINIMUM SPACE REQUIREMENTS Place the printer near the power source providing clearance as shown G024I503 WMF A More than 5 cm 2 0 B...

Page 96: ...12 A 187 276 V 50 60 3 Hz More than 6 A 2 Permissible voltage fluctuation 10 3 Do not set anything on the power cord NOTE 1 Make sure the plug is firmly inserted in the outlet 2 Avoid multi wiring 3 5...

Page 97: ...lacement and Adjustment Procedures to remove the oil supply unit of the fusing unit Gradually tilt the oil sump to move oil from oil sump A to the oil bottle B 3 After moving the oil to the oil bottle...

Page 98: ...the service manual for the controller These two modes contain different functions 4 2 ENGINE SP MODE 4 2 1 OVERVIEW Entering engine SP mode To enter engine SP mode hold down the Online A and Menu B ke...

Page 99: ...tion 10 Image Adjust Adjustment of image reproduction ratio in the main scan and sub scan directions 11 Output Check Tests for motors clutches and solenoids 12 Hi light Fine adjustment of density for...

Page 100: ...played after the last item In the lowest level of the menu the currently selected item setting is prefixed with an asterisk To select an item setting press the Enter key while the target item is displ...

Page 101: ...rays tray 2 tray 3 and the by pass tray in the same way as tray 1 Margin Print Thick Paper Print Thick By pass Tray Margin Pattern Print Margin Print Transparency Print Trans By pass Tray Margin Adjus...

Page 102: ...al lines of the grid patterns X and Y in the diagram 3 Move to the Adjust menu to adjust the vertical and horizontal registrations The adjustment range for the horizontal Left registration is between...

Page 103: ...High Parameter Thick Paper Same as Std Paper Same as Std Paper Maintenance 2 Parameter Parameter Transparency Same as Std Paper Same as Std Paper 4 2 5 CLEAR MEMORY Use this menu to reset all the set...

Page 104: ...ed Paper not detected Paper End Sensor Tray 2 P End 2nd Paper detected Paper not detected Paper End Sensor Tray 3 P End 3rd Paper detected Paper not detected Registration Sensor Registration Paper not...

Page 105: ...tus of the paper size switches for paper size detection 0 Pressed 1 Not pressed 2 The table below shows the correspondence between the paper guide positions and displayed values Guide position A3W A3...

Page 106: ...patches on the transparency due to heating For details of the operation see Replacement and Adjustment Checking and Adjusting the Fusing Nip Width The table below shows the details of the Nip Width m...

Page 107: ...Color Bias Process control for setting color development bias Only the color development bias initialization step is done PCU Getting OK Complete process control followed by belt lubrication routine f...

Page 108: ...ble below shows the Test Print menu details Layer 1 Layer 2 Layer 3 Layer 4 Test Print Pattern 1 Pattern 1 Tray X Printing Tray X Test Print Pattern 2 Same as Pattern 1 Same as Pattern 1 Maintenance 8...

Page 109: ...machine but keep it connected The table below shows the Output Check menu details Layer 1 Layer 2 Layer 3 Layer 4 Maintenance 11 Output Check Out Put Check XXXXXXXX XXXXXXXX ON OFF Name Display Operat...

Page 110: ...ting OFF Main Mtr normal Operating until inputting OFF Main motor Main Mtr slow Operating until inputting OFF Polygon mirror motor Scanner Motor Operating until inputting OFF Revolver motor Revolver M...

Page 111: ...elt lubrication interval is adjustable The counter for this interval increases by one for each transfer belt revolution e g It increases by 4 with A3 DLT full color printing and by 1 in monochrome mod...

Page 112: ...tment in the manual for the optional 500 sheet paper tray CAUTION When replacing components be aware that the fusing unit may be hot Handle it with care 5 1 2 CLEANING Clean the printer components whe...

Page 113: ...in the PCU Quenching lamp I Blower brush if dirty ID sensor C Dry cloth Dust shield glass C 1 Cleaner blush P N G0241533 Fusing unit R 2 1 This is a common item with user maintenance 2 The amount per...

Page 114: ...1 Replacement Adjustment 6 REPLACEMENT AND ADJUSTMENT 6 1 EXTERIOR 6 1 1 RIGHT COVER OZONE FILTER COVER 1 Remove the ozone filter cover A 2 Remove the ozone filter B 3 Remove the right cover C four s...

Page 115: ...EXTERIOR 31 March 1999 6 2 6 1 2 LEFT COVER 1 Open the oil bottle cover A Remove the left cover B three screws G024R152 WMF A B...

Page 116: ...ER AND OPERATION PANEL 1 Open the by pass tray A 2 Remove two screws B and carefully lift the front cover C from the printer 3 Remove the operation panel D from the front cover two hooks Make sure to...

Page 117: ...4 6 1 5 TOP COVER AND TOP REAR COVER 1 Open the oil bottle cover A Remove the two screws holding the top cover B then slide and remove the top cover B 2 Remove the top rear cover C two screws G024R16...

Page 118: ...exposure to light 2 When rotating the PCU holder with the PCU removed be careful not to touch the detection face of the ID sensor 3 Do not turn the PCU joints A manually Otherwise the transfer belt B...

Page 119: ...999 6 6 6 2 2 ID SENSOR 1 Remove the PCU 2 Remove the ID sensor A 1 screw 1 connector B NOTE Calibrate the new ID sensor after installing it Follow the steps described in Calibrating the ID sensor on...

Page 120: ...tern 3 to print pattern 3 Select a tray with paper in it NOTE Test printing is executed continuously To stop test printing press the Escape or Menu key 5 Check the test print If the YCM solid areas of...

Page 121: ...ch A two hooks Make sure to unplug the connector 3 Remove the right cover See Right Cover Removal 4 Remove the PCU reset sensor B four hooks one connector 5 Remove the quenching lamp and its bracket C...

Page 122: ...SENSOR PAPER END SENSOR Pull out sensor 1 Remove the PCU 2 Remove the pull out sensor A four hooks one connector B Paper end sensor 1 Remove the paper end sensor bracket C one screw 2 Remove the paper...

Page 123: ...g unit See Fusing Unit Removal 2 Remove the oil end sensor A two hooks one connector B 3 Remove the exit cover switch bracket C one screw two connectors 4 Remove the exit cover switch D two screws NOT...

Page 124: ...Cover Removal 2 Remove the door safety switch A two screws six connectors 3 Remove the top flywheel B three screws 4 Loosen the tightener C and remove the PCU timing belt from the motor shaft 5 Remove...

Page 125: ...4 Remove the bracket assembly B six screws one E ring C one bearing D two connectors E 5 Remove the development drive solenoid F and or transfer belt cleaning solenoid G 6 After replacing the developm...

Page 126: ...utput test menu to turn on the development drive solenoid See Section 4 Output Check 9 Set the adjustment tool P N G0249310 F between the development joint E and right side plate D For this step the p...

Page 127: ...t B four screws NOTE When installing the PCU drive unit make sure that the arm is set in the constrictions of the two joints Also set the joint pressure springs C between the pressure arm protrusion a...

Page 128: ...h 1999 INSIDE THE MAIN UNIT 6 15 Replacement Adjustment 6 2 11 REVOLVER MOTOR 1 Remove the right cover See Right Cover Removal 2 Remove the revolver motor unit A three screws one connector B G024R901...

Page 129: ...t to drop toner onto the floor Before placing the DTM unit on the floor lay down a sheet of paper first 2 After installing a new DTM unit remove the seal Then close the DTM cover and turn on the print...

Page 130: ...C and K DTM units B NOTE Do not hold and turn the DTM units by hand as this puts too much load on the revolver motor Hold and turn the revolver motor to move the DTM units to the removal position 4 L...

Page 131: ...Remove the development top cover A three screws 6 Remove the development bottom cover B two screws and 3 hooks 7 Remove the LD unit C two screws one connector D CAUTION Do not loosen the painted screw...

Page 132: ...cover see Bottom Front Cover Removal and tray cover see Controller Board Removal 2 Remove the fusing unit See Fusing Unit Removal 3 Remove the PCU reset sensor from the bracket See PCU Reset Sensor Re...

Page 133: ...ical housing unit G four screws two connectors H lifting it in the direction of the arrow in the diagram NOTE When putting back the optical housing unit check that the positioning boss on the housing...

Page 134: ...justment 11 Remove the optical housing unit cover I four screws and two hooks NOTE When removing or putting back the bracket be careful not to touch the polygon mirror faces 12 Remove the polygon mirr...

Page 135: ...he engine SP menu to release the SC 4 When the fusing unit has been replaced execute S3 Maintenance Clear in the controller SP menu to reset the fusing counter 1 Remove the top cover See Top Cover Rem...

Page 136: ...pressure spring retaining screw has been turned while replacing the pressure or hot roller adjust the nip width See Checking and Adjusting the Fusing Nip Width for details 1 Remove the fusing top cov...

Page 137: ...ch 1999 6 24 4 Remove the exit guide See Exit Sensor Removal 5 Remove the oil supply unit A two screws 6 Remove the holder B for the right fusing lamp terminals three screws three connectors G024R172...

Page 138: ...SECTION 6 25 Replacement Adjustment 7 Remove the holder A for the left fusing lamp terminals two screws five connectors 8 Extract the pressure roller lamp B 9 Extract the hot roller lamp C G024R174 WM...

Page 139: ...n Make sure that the cables are connected to the correct places Pressure roller lamp connector a A Hot roller lamp connector b B Pressure roller thermofuse connector c C Hot roller thermofuse connecto...

Page 140: ...inter 2 Remove the oil supply felt cover B four washers and four screws 3 Remove the upper oil supply felt C three screws NOTE When installing the upper oil supply felt on the oil pan place it on the...

Page 141: ...E When installing the oil supply stay ensure that the notch fits over its counterpart 5 Remove the oil supply sub roller B two E rings and two bearings 6 Remove the oil supply roller C two E rings and...

Page 142: ...the exit bottom guide B two screws NOTE When installing the exit bottom guide put the paper exit feeler C under the guide notch D as shown in the diagram 2 Remove the exit guide E one snap ring F one...

Page 143: ...ON 31 March 1999 6 30 Paper exit sensor 3 Remove the paper exit sensor A one screw and four hooks Cleaning roller 4 Remove the cleaning roller B two E rings one gear two springs and two bearings G024R...

Page 144: ...reinstalling it The right and left screw holes are intended for adjusting the inlet path in the event of wrinkling or other similar feed problems 2 Remove the fusing stay B two screws NOTE Be careful...

Page 145: ...Remove the hot roller A two C rings two bearings and one gear 7 Remove the inlet guide plate B two screws 8 Remove the hot roller thermistor C one screw 9 Remove the hot roller thermofuse D one screw...

Page 146: ...th mode 2 Wait until the transparency is ejected For each of the three altered bands measure the width at 10 mm from both the right and left ends and at the center If the widths of the altered bands f...

Page 147: ...ow direction less nip width Troubleshooting 1 Wrinkles Adjust the nip width to the upper limit of the standard L 6 7 mm R 7 1 mm After adjustment check that worm like images do not appear 2 Worm like...

Page 148: ...s added optional expansion memory or a NIC remove it before controller replacement Remember to install the memory or NIC on the new controller board 4 Remove the controller cover E 16 screws including...

Page 149: ...lacement 1 Remove the fusing unit see Fusing Unit Removal and the controller board see Controller Board Removal 2 Remove the bracket A two screws 3 Remove the eight screws retaining the electrical wir...

Page 150: ...31 March 1999 ELECTRICAL WIRING 6 37 Replacement Adjustment 4 Remove the power supply unit C six screws six connectors G024R254 WMF C...

Page 151: ...nel unplug connectors from the power supply unit and the high voltage supply unit as necessary 3 Remove the high voltage supply unit B four screws two hooks eight connectors CAUTION Carefully connect...

Page 152: ...rews 18 connectors NOTE When replacing an MCU remove the NVRAM chip IC106 from the old board install it on the new board then install the new board In the event of NVRAM damage install a new NVRAM chi...

Page 153: ...in the IC card is later than the current one Press the On Line key 6 Check that the messages on the operation panel change in the following sequence 7 Upon the OK OK message the MCU flash ROM has bee...

Page 154: ...PASS PAPER END SENSOR REGISTRATION SENSOR 1 Remove the front cover See Front Cover Removal 2 Remove the paper end sensor bracket A one screw 3 Remove the by pass paper end sensor B one connector and...

Page 155: ...Removal 2 Remove the by pass feed table unit A two snap rings two hooks one connector B 3 Remove the auxiliary tray C two hooks from the cover D for the by pass feed table 4 Remove the table E two ho...

Page 156: ...l 2 Remove the paper end sensor bracket See By pass Paper End Sensor Removal 3 Remove the pad bracket A three screws 4 Remove the transport guide plate B two screws 5 Remove the pick up roller C one s...

Page 157: ...rch 1999 6 44 6 6 4 PAPER FEED ROLLER 1 Remove the paper feed tray 2 Pull down the front bottom cover forward Slide the lever A in the direction of the arrow in the diagram and remove the paper feed r...

Page 158: ...screw each 3 Open the paper feed frame and unplug the ID sensor connector Pull out the right and left rotation shafts F until the PCU holder E can be removed NOTE Do not entirely pull out the rotation...

Page 159: ...999 6 46 6 6 6 TRANSFER ROLLER POSITION SENSOR BY PASS PAPER FEED CLUTCH REGISTRATION CLUTCH AND TRANSFER ROLLER CLUTCH 1 Remove the right inner cover A three screws 2 Remove the front cover See Front...

Page 160: ...h C one hook one connector D Registration clutch 5 Remove the registration clutch E one hook one connector F Transfer roller clutch 6 Remove the bracket G two screws 7 Remove the transfer roller clutc...

Page 161: ...the transfer roller A three E rings one gear and two bearings 6 6 8 REGISTRATION ROLLER IDLER 1 Remove the front cover See Front Cover Removal 2 Remove the right inner cover three screws See Transfer...

Page 162: ...registration roller idler see Registration Roller Idler Removal 2 Remove the registration clutch A one hook one connector B NOTE When putting back the registration clutch put the stopper on the bent...

Page 163: ...l it disconnects from the tray paper feed clutch C NOTE Rotate the shaft into the correct orientation when putting it back into the clutch The shaft and the hole for the shaft in the clutch are D shap...

Page 164: ...djustment Pull out clutch 4 Remove the pull out clutch bracket A two screws 5 Remove the pull out clutch B one bearing one connector C Relay roller clutch 6 Remove the relay roller clutch D one hook o...

Page 165: ...and the LCD displays an SC error message The error is logged TYPE 2 Immediate shutdown The printer stops immediately and the LCD displays an SC error message The error is logged TYPE 3 Log only Proce...

Page 166: ...lamp connector 24 Type 1 Hot roller thermistor error The roller temperature has been 0 C for five seconds No detection in the event of a jam door open SC unit absence energy saving mode or lack of fus...

Page 167: ...or 240 ms Detection starts 60 ms after control starts for this component There is disconnection in the charge corona unit bias supply circuit Dirty or deformed electrodes 34 Type 2 Charge corona unit...

Page 168: ...component There is disconnection in the paper transfer bias supply circuit Dirty or deformed electrodes 48 Type 2 Paper transfer negative current error A D converted voltage has been 4 8 V or more fo...

Page 169: ...of a jam door open SC unit absence energy saving mode or fusing unit absence Hot roller thermistor hot roller lamp connector MCU 57 Type 2 Print command error When an abnormal combination of print com...

Page 170: ...allation development bias error MCU LD control malfunction loss of synchronization 111 Type 3 ID sensor pattern error Magenta The slope M of the line representing the relationship between the M develo...

Page 171: ...3 Type 3 ID sensor pattern error K The slope M of the line representing the relationship between the DTM bias and attached toner amount is not between 0 01 and 0 001 K DTM bias control Incorrect DTM i...

Page 172: ...the first sheet is printed Paper end is detected by the by pass feed paper end sensor Supply paper Double image mode Two images on the transfer belt at the same time Load xx Tray 1 Printing is disabl...

Page 173: ...printed The used toner bottle is detected as full for 10 seconds Replace the used toner bottle The near full status is reset if the full used toner bottle status is not detected continuously for 10 se...

Page 174: ...o the home position Reset Fusing Unit Correctly Printing is disabled Disconnection is detected for both the hot and pressure roller thermistors when the main switch turns on Install the fusing unit co...

Page 175: ...24 s 3 82 s Remove the jammed paper and close the front cover Tray 2 Option 0 9 s 3 9 s 4 08 s Remove the jammed paper and close the front cover Paper feed jam Printing is disabled Tray 3 Option 0 9 s...

Page 176: ...paper 2 18 seconds after the registration sensor de activates The following conditions are regarded as roll in jams however an exit jam message is displayed The exit sensor is de activates less than t...

Page 177: ...et fan FM5 E1 16 Inlet fan FM4 D8 17 Transport fans FM1 FM3 C8 SWITCHES Index No Description Symbol P to P 1 Main switch SW1 B3 2 Exit cover switch SW2 C7 3 Door safety switches SW3 B7 4 Paper size sw...

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Fresa G024, Service Manual

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