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Ricoh FW 810, Service Manual

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Ricoh FW 810 Service Manual Download Page 159

8.4 PAPER FEED ROLLER/REGISTRATION ROLLER

REPLACEMENT

 1. Remove the manual feed table [A] (1 screw), lower feed guide plate [B]

(6 screws), and the lower registration guide plate [C] (4 screws).

 2. Remove the paper feed clutch [D] (2 Allen screws) and the registration

clutch [E] (1 Allen screw, 1 connector).

 3. Remove the collar

[F] (1 Allen
screw); then, re-
move and replace
the paper feed
roller [G] (2 E
rings, 2 bushings).

[A]

[B]

[C]

[D]

[E]

[F]

[G]

6 January 1990

5-37

Summary of Contents for FW 810

Page 1: ...SECTION 1 OVERALL MACHINE INFORMATION...

Page 2: ...otoconductor Organic photoconductor drum Drum Charge Single wire with grid plate Negative Charge Reproduction Ratio 1 1 0 5 Exposure System Slit exposure via fiber optic array Exposure Lamp Fluorescen...

Page 3: ...ers Fusing Lamp Halogen lamp 115 V 1 100 W 220 240 V 1 100 W Self diagnostic Codes 14 codes displayed in copy counter Power Source 115 V 60 Hz 12 A 220 V 50 Hz 7 A 240 V 50 Hz 7 A Power Consumption Ma...

Page 4: ...24 25 26 2 1 Manual Image Density Indicators Show the image density level selected by the Lighter and Darker keys 2 Lighter Copy Indicator There are 14 manual ID levels but only 7 manual ID LEDs The...

Page 5: ...mpty the toner collection bottle 14 Call Service Indicator Indicates that there are functional problems within the copier 15 Copy Counter Displays the number of copies entered the number of copies mad...

Page 6: ...be inserted Turns off when an original is inserted 2 Stop Key Press to stop the copier during a copy cycle emergency stop 3 Insert Copy Paper Indicator Lights when the machine is ready for a sheet of...

Page 7: ...ecause the photoconductive drum has a high electrical resistance in the dark 2 Exposure High intensity light from a fluorescent lamp is reflected from the moving original through the fiber optic array...

Page 8: ...ed image on the drum surface Then a strong negative charge is applied to the back side of the paper The negative charge pulls the toner particles from the drum surface onto the paper 6 Paper Separatio...

Page 9: ...s 17 4th Press Rollers 18 2nd Press Rollers 19 Rear Original Feed Roller 20 3rd Press Rollers 21 Quenching Lamp 22 Upper Exit Rollers 23 Upper Exit Sensor 24 Exit Rollers 25 Exit Gate 26 Exit Detector...

Page 10: ...tch 14 Paper Feed Drive Chain 15 Development Drive Belt 16 Paddle Roller Gear 17 Registration Roller Clutch 18 Drum Drive Gear 19 Toner Collection Coil Gear 20 Feed Fusing Drive Belt 2 21 Fusing Drive...

Page 11: ...6 ELECTRICAL COMPONENT LAYOUT 6 1 MIDDLE AND UPPER SECTIONS 6 2 1 3 4 5 7 8 9 10 12 11 13 14 15 16 17 19 20 18 22 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 39 6 January 1990 1 10...

Page 12: ...6 2 LOWER AND FUSING SECTIONS 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 61 62 63 64 65 59 6 January 1990 1 11...

Page 13: ...29 Operation Panel 30 Pre Transfer Lamp 31 ID Sensor 32 Pick off Pawl SOL 33 Registration Sensor 34 2nd Feed Detector 35 1st Feed Detector 36 Toner Density Sensor 37 Paper Stopper SOL 38 Original Exi...

Page 14: ...utch Drives the registration rollers 45 Solenoids SOL1 Toner Supply Solenoid Turns on to supply toner to the development unit 43 SOL2 Pattern Shutter Solenoid On ID check cycles this solenoid turns on...

Page 15: ...d and the main motor when the toner cartridge cover is opened 42 SW6 Auto Feeder Safety Switch Prevents main motor operation when the auto feeder is not set 59 Sensors and Detectors S1 Image Density S...

Page 16: ...h the upper exit guides 15 S17 Lower Exit Sensor Monitors copy paper movement through the lower exit guides 17 S18 Auto Sheet Feeder Sensor Detects misfeeds in the auto sheet feeder S19 Paper End De t...

Page 17: ...P2 Transfer Sepa ration Power Pack Provides high voltage power for the transfer corona and separation coronas 47 Thermistors TH1 Hot Roller Thermistor Monitors the hot roller s surface temperature 49...

Page 18: ...nter Keeps track of the total length of copies made 61 NF Noise Filter Filters electrical noise on the ac power input lines 57 TR Transformer Steps down the line voltage to 100 Vac TR Triac Provides a...

Page 19: ...ing Fan M4 Vacuum Fan M5 Lamp Regulator PCB4 Exposure Lamp L1 CN1 1 2 CN3 1 2 CN3 4 5 Triac T309 T1 T310 G T308 Fusing Lamp L3 Thermofuse x2 AC Controller 1 PCB3 T307 T305 T306 T304 CN401 1 CN401 2 M1...

Page 20: ...wall outlet ac power The main board controls the fusing lamp through the triac The transformer steps the ac power down to 100 volts and then provides it to the main switch If the main switch is off po...

Page 21: ...CN2 2 and CN2 7 respectively to the main board Also 24 volts Va is provided to the charge bias power pack from CN2 6 and to the transfer separation power pack from CN2 8 CN1 1 AC LINE CN1 3 AC NEUTRAL...

Page 22: ...SECTION 2 DETAILED SECTION DESCRIPTIONS...

Page 23: ...ion and good reproduction of low contrast originals pencil originals etc 1 2 HANDLING THE DRUM The organic photoconductor drum is very sensitive to light temperature and corrosive gases Please observe...

Page 24: ...ed to the drum as follows main motor drive gear C idle gear D main drive pulley gear E drum drive belt F drum drive gear G drum flange H drum When the drum knob I is tightened the right flange J press...

Page 25: ...hen a high negative voltage is applied to it by the charge grid power pack P1 To make the negative corona uniform a grid consisting of 8 wires is installed on the charge corona unit between the corona...

Page 26: ...even charge is applied to the drum surface When developing the test pattern for the image density sensor the grid charge is 460 volts The copy grid voltage and ID sensor grid voltage amounts can be ad...

Page 27: ...e platen roller D presses the original E flat against the exposure glass F just above the fiber optic array This ensures that the image is properly focused The original must be within 0 2 mm of the ex...

Page 28: ...sheet of copy paper is fed Just before the copy paper reaches the registration sensor the original feed clutch turns on again and original feed resumes The original passes between the platen roller I...

Page 29: ...riginal drive pulley through original drive belt 2 A When the original drive clutch B is energized original drive belt 3 C starts turning the front original feed rollers and the original registration...

Page 30: ...ginal set detector in the down position while copying This is accomplished by the original stopper solenoid A When the original stopper solenoid turns on the stopper arm B rotates against the feeler o...

Page 31: ...ither by the image density selected from the operation panel manual ID control or by the original s background level as sensed by the ADS The CPU uses the light sensor to monitor the actual light inte...

Page 32: ...sity of the light output by the exposure lamp as measured by the light sensor is fixed This is shown in the above graph For manual ID levels 2 through 7 the development roller bias also varies See the...

Page 33: ...mage density sensing ADS is used the exposure light intensity varies depending on the background image density of the original The preceding table shows how the exposure light intensity changes depend...

Page 34: ...white plate standard white which is located above the ADS prior to the arrival of the original This standard white level VSD is used for comparison with the background level of the original VOD The AD...

Page 35: ...the peak hold function The resistance of PD401 varies with the strength of the light striking it The two op amps amplify the effect of the change in PD401 and output the ADS signal at CN401 3 CN401 2...

Page 36: ...source The output of the exposure lamp varies depending on the temperature low temperatures especially degrade the light output To prevent fluctuations in temperature from affecting the copy image the...

Page 37: ...ircuit drops CN107 B3 to LOW The copier then stops operation the Call Service Indicator wrench mark lights and E and 8 are alternately displayed in the Copy Counter If there exposure lamp thermistor c...

Page 38: ...the negatively charged areas of the drum surface attracts and holds the positively charged toner In this way the latent image is developed Negative bias is applied to the development roller to preven...

Page 39: ...r gear D and the paddle roller gear E The auger gear F is engaged with the paddle roller gear Thus the development roller paddle roller and auger all turn when the development drive motor is on The to...

Page 40: ...by the doctor blade B One part the magnetic brush goes on to develop the latent image on the drum However the other part is trimmed off by the doctor blade and directed to the backspill plate C As the...

Page 41: ...ity is too low toner is added The secondary sensor is the toner sensor It measures the ratio of toner to carrier in the developer This sensor is used only if the output of the ID sensor is abnormal or...

Page 42: ...calculated from eight samples of sensor pattern reflectivity These two values are then compared to determine whether toner should be added or not as follows No toner supply condition Vsp Vsg 0 125 To...

Page 43: ...ty every 1220 mm If Vsp Vsg becomes greater than 0 125 1 8 then it starts checking toner density every 610 mm If service program mode 21 is set to 1 the toner density will be checked every 610 mm rega...

Page 44: ...ontrol signal applied from CN101 1 The input signal from the sensor is applied to CN101 2 This is an analog signal When the toner density is at the standard level the analog signal is approximately 2...

Page 45: ...dirty background on the copy The development bias prevents such dirty background A negative bias a little larger than the residual charge is applied to the development roller This prevents the positiv...

Page 46: ...re section 4 5 4 Bias Adjustment Using service program mode 19 the bias level can be increased or decreased as shown in the above chart 280 240 200 180 Normal ADS 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9...

Page 47: ...lectric properties of the developer as a new developer mixture is broken in The following table shows this correction Notice that the correction depends on the average Vsp Vsg ratio as measured during...

Page 48: ...e toner through small holes 0 5 mm in a plastic strip C along one side of the toner cartridge The toner particles thus ejected from the cartridge fall into the development unit and are mixed into the...

Page 49: ...e ions These negative ions are applied to the copy paper and the negative charge attracts the positive charged toner away from the drum and onto the paper In addition the paper is held against the dru...

Page 50: ...rotates clockwise and pushes up the pawl holder C This releases the two pick off pawls D allowing them to rotate against the drum Just after the leading edge of the copy paper passes the transport sen...

Page 51: ...onverter and dc ac inverter circuits then apply approximately ac 4 0 kV and 200 V to the separation corona wires Normally T Sel is not used However if the user presses the Auto Image Density key for l...

Page 52: ...ops onto the toner collection coil B which then moves it to the used toner tank The cleaning blade pressure spring applies pressure to the exact center of the cleaning blade so that pressure is evenly...

Page 53: ...originals and 80 transfer efficiency The toner overflow sensor C detects when the used toner tank is full The toner collection bottle is vibrated to prevent used toner from building up in one place a...

Page 54: ...stays off When toner presses against the tuning fork the resistance of the piezoelectric elements that are in contact with the tuning fork changes and the vibrating frequency increases The frequency d...

Page 55: ...main motor The quenching lamp consists of two PCBs containing 49 LEDs light emitting diodes each The LEDs output light in the 660 nm to 700 nm red range The main board turns on the quenching lamp LED...

Page 56: ...feeds through the manual feed rollers automatically after the original is inserted Just before the paper reaches the registration rollers it activates the registration sensor D The manual feed solenoi...

Page 57: ...the manual feed solenoid C is energized the paper feed drive chain D drives the manual feed roller E Once the paper reaches the registration sensor the registration clutch F turns on thus the registr...

Page 58: ...om the vacuum fan C holds the paper firmly against the belts so that there is enough friction between the paper and the belts for smooth transportation of the paper The transport belts and transport r...

Page 59: ...ressure is constantly applied by the pressure levers at the ends of the fusing unit The fusing lamp C which is located at the hot roller axis is turned on and off to maintain the operating temperature...

Page 60: ...r goes through the upper copy exit path The exit direction is selected using the Copy Exit Way key A steel cleaning roller K removes toner from the pressure roller This effectively cleans toner from b...

Page 61: ...wn The pressure roller is friction driven by the hot roller The fusing rollers turn constantly when the main motor A is on driven via the gears B through feed fusing drive belts 1 C and 2 D the sprock...

Page 62: ...exit rollers are driven by the main motor C via a set of gears D Finally the exit roller drive chain E drives the exit rollers through a sprocket as shown above The exit rollers turn constantly when t...

Page 63: ...which in turn energizes the drive circuit The drive circuit turns on the triac to complete the lamp circuit thus turning on the lamp RA301 guards against a failure of the 24 volt power supply When 24...

Page 64: ...t pin 5 of IC107 increases If this voltage becomes greater than the voltage at pin 6 the output at pin 7 becomes HIGH Q101 then turns off and cuts the 24 volt supply to ac controller 2 The fusing lamp...

Page 65: ...and pressure roller can be adjusted using service programs 28 and 29 These programs are used to compensate for variations in the response of different thermistors Service program 28 adjusts the hot r...

Page 66: ...disk with slots in it within a photointerruptor As the disk rotates light from the LED activates the phototransistor each time a notch comes between them The pulse interval is 3 125 milliseconds If n...

Page 67: ...nergized The CPU monitors the KEY lines KEY1 to KEY3 to determine if a key has been pressed Each KEY line is used to monitor up to four keys on the operation panel A specific scan pulse appears at the...

Page 68: ...hine Name Symbol CN 1 CN 2 Toner Supply SOL1 CN104 B10 CN104 A10 Pattern Shutter SOL2 CN104 B13 CN104 A13 Exit Gate SOL3 CN109 10 CN109 11 Pick off SOL4 CN104 B11 CN104 A11 Paper Stopper SOL6 CN104 B1...

Page 69: ...slot light from the LED is blocked and the output becomes open In this machine a 5 volt pulse is present at CN 2 when the output is open This machine uses three different types of photointerruptor as...

Page 70: ...105 B2 CN105 A3 CN105 B3 2nd Original Transport Detector S7 CN105 A1 CN105 B1 CN105 A2 Original Exit Detector S9 CN106 A17 CN106 B17 CN106 B18 Recycle Gate Detector S10 CN106 A17 CN106 B14 CN106 B18 1...

Page 71: ...lamp turns on CODE E4 Hot Roller Thermistor Short Code E4 blinks if the resistance of the thermistor TH1 is 0 1 k or less 2 minutes after the fusing lamp turns on CODE E5 Pressure Roller Thermistor Op...

Page 72: ...ity Sensor Code Ed blinks if the sensor voltage Vts becomes less than 1 6 volts or more than 4 7 volts for 1 minute CODE EF Abnormal Condition in ID Sensor Code EF blinks if the ID sensor photosensor...

Page 73: ...SECTION 3 INSTALLATION...

Page 74: ...s follows a Where it will not be subjected to sudden temperature changes from low to high or vice versa b Where it will not be directly exposed to cool air from an air conditioner in the summer c Wher...

Page 75: ...1 1 MINIMUM SPACE REQUIREMENTS 1 Front 1 000 mm 39 5 in 2 Back 600 mm 24 in 3 Right 600 mm 24 in 4 Left 600 mm 24 in 600 mm 600 mm 600 mm 1000 mm 6 January 1990 3 2...

Page 76: ...tion 10 3 Permissible Extension Cord At least 300 V 30 A capacity and less than 5 m 5 5 yd long NOTE a Be sure to ground the machine Do not connect the grounding wire to a gas pipe b Make sure the plu...

Page 77: ...Copy Guide 1 pc 2 Original Guide 2 pcs 3 Left Inner Cover Bracket 1 pc 4 Pick off Pawl Unit 1 pc 5 Right Inner Cover 1 pc 6 Left Inner Cover 1 pc 7 Inner Cover Bracket 1 pc 8 Pan head Screw M4 x 6 16...

Page 78: ...PING RETAINERS 1 Remove all strips of shipping tape and accessories 2 Open the original feed unit A and re move the two spac ers B from the platen roller bear ings and remove the protective sheet from...

Page 79: ...ng the main board bracket E and open the board 90 degrees 5 Remove the plate F 4 screws fixing the right portion of the upper unit on the lower unit Keep two screws for mounting the fix ing plate late...

Page 80: ...xing the left portion of the upper unit on the lower unit 8 Press up the handle A and open the middle unit B 9 Install the fixing plate C with the two screws Then reinstall the main board bracket G B...

Page 81: ...it C and fix the unit with two knob screws D Make sure that the two po sitioning pins of the main copier are in serted in the two holes of the pick off pawl unit 3 Remove the drum protection sheet E b...

Page 82: ...el I in the space between the cartridge cover and the developer entrance 8 Adjust the level of the machine by turn ing the bolts on the 4 machine feet 3 3 SUPPLYING DEVELOPER 3 kg 1 Open the original...

Page 83: ...and the origi nal feed unit 8 Press the Lighter key once 9 Press the Copy Exit Way key E to turn on the development motor Press the Copy Exit Way key again after 2 or 3 seconds to turn the motor off 1...

Page 84: ...3 4 SUPPLYING TONER 1 Set the toner car tridge A as shown in the figure 2 Remove the sealing tape B on the car tridge and turn the knob C clockwise unit it stops A B C 6 January 1990 3 11...

Page 85: ...itch 4 Press the Lighter key A four times so that the fourth segment from the right of the copy density indicator lights 5 Press the Plus key B once then press the Paper Exit Se lect key C 6 Turn off...

Page 86: ...et F on the lower unit Use 2 pan head screws for the bracket Use 1 flat head screw and 3 pan head screws for the right inner cover 3 Install the right mid dle cover 4 screws 4 Install the left inner c...

Page 87: ...7 MOUNTING GUIDES 1 Install the copy guide A Use the two screws that are already in the cor rect position on the top unit 2 Set the two original guides B as shown in the figure A B 6 January 1990 3 1...

Page 88: ...SECTION 4 SERVICE TABLES...

Page 89: ...ler C C C C C C Clean with a damp cloth 5 Press rollers I C C Clean with a damp cloth 6 White plate C C C C C C Clean with a damp cloth 7 AD sensor C C C C C Clean with a blower brush 8 Timing belts I...

Page 90: ...ing C C Clean with a dry cloth 4 T S corona end block casing C C C C C C Clean with a dry cloth 5 Ozone filter R R R R R 6 Quenching lamp I I I I C Clean with a dry cloth or blower brush 7 Pick off pa...

Page 91: ...with a damp cloth 5 Spring clutch L Lubricate with Mobil Temp 78 6 Registration roller brake I I I I I G Fusing ______________________________________________________ EM 3 6km 7 2km 10 8km 14 4km 18km...

Page 92: ...ary 4 Relay rollers C C C C C Clean with a damp cloth 5 Paper feed guide plate Clean with a damp cloth as needed 6 Spring clutch L Lubricate with Mobil Temp 78 7 Teflon tape R I Others _______________...

Page 93: ...6 Ground 107 Vc 5 volts 108 Va 24 volts 2 2 DIP SWITCHES NO OFF ON 1 Normal Free run one A1 sideways feed cycle feed original to start 2 Normal Forced Ready condition no warm up 3 Length counter Copy...

Page 94: ...priate image density level and lead edge erase amount 5 Set the appropriate number in the copy counter using the Plus and Minus keys 6 Press the Copy Exit Way key 3 1 2 Service Program Table Number ID...

Page 95: ...set 8 Count UP DOWN 0 Count UP 1 Count DOWN 9 Key Tone 0 Key tone ON 1 Key tone OFF 10 Default ID Setting 0 Auto ID sensing 1 Manual ID level 4 11 Default Paper Feed 0 Auto Sheet Feeder 1 Manual Feed...

Page 96: ...itial conditioning the ID Sensor Bias is 340 V 19 Dev Bias Adjustment 0 0 1 40 V 2 20 V 3 20 V 4 40 V 20 ADS Basic Level Setting 0 Normal 1 Lighter 2 Darker Lighter Copy Auto Image Density 20 mm 15 mm...

Page 97: ...ry setting 1 10 mm 2 5 mm 3 0 mm 4 5 mm 5 10 mm 6 15 mm 7 20 mm 8 25 mm 9 30 mm 26 Fine Registration Adjustment 0 25 mm step 0 0 mm 1 1 0 mm 2 0 75 mm 3 0 5 mm 4 0 25 mm 5 0 25 mm 6 0 5 mm 7 0 75 mm 8...

Page 98: ...C 7 6 C 8 8 C 9 10 C 29 Pressure Roller Temperature Adjustment 0 0 C 1 8 C 2 6 C 3 4 C 4 2 C 5 2 C 6 4 C 7 6 C 8 8 C 9 10 C 32 Fusing Roller Pressure Roller Temperature Display F Fusing roller P Pres...

Page 99: ...White Plate F Vod Vsd 41 Endless Repeat 0 Normal 1 Endless 42 Total Original Jams 43 Original Jams Upper Transport Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Densit...

Page 100: ...mage Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm...

Page 101: ...bnormal _ Normal 1 If a line is drawn through Lighter Copy or Auto Image Density it means that the indicator is off 2 These service programs are provided for testing the machine in the field Lighter C...

Page 102: ...he image density level and lead edge erase amount that are appropriate for the sensor you want to check If the sensor is active the Upper Exit Indicator will light If it is not active the Lower Exit I...

Page 103: ...Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5...

Page 104: ...Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm...

Page 105: ...n Signal 26 Thermistor TH3 Short Signal 1 If a line is drawn through Lighter Copy or Auto Image Density it means that the indicator is off Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighte...

Page 106: ...y level and lead edge erase amount that are appropriate for the component you want to test 5 Use the Copy Exit Way key to turn the electrical component ON and OFF When the selected component is ON 1 i...

Page 107: ...ter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 1...

Page 108: ...m 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Imag...

Page 109: ...Manual ID level 7 Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto...

Page 110: ...er T Trig and Select T Sel Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter Copy Auto Image Density 20 mm 15 mm 10 mm 5 mm Lighter...

Page 111: ...in the copy counter when the component is ON and the decimal point is off when the component is OFF 66 Development Bias 2 Levels 0 to 9 0 0 V 1 60 V 2 60 V 3 80 V 4 100 V 5 120 V 6 140 V 7 160 V 8 18...

Page 112: ...evels 20 to 29 0 420 V 1 440 V 2 460 V 3 480 V 4 500 V 5 520 V 6 540 V 7 560 V 8 580 V 9 600 V 69 Grid Voltage Levels 0 to 9 0 0 V 1 380 V 2 400 V 3 420 V 4 440 V 5 460 V 6 480 V 7 500 V 8 520 V 9 540...

Page 113: ...V 9 760 V 71 Grid Voltage Levels 20 to 29 0 780 V 1 800 V 2 820 V 3 840 V 4 860 V 5 880 V 6 900 V 7 920 V 8 940 V 9 960 V 1 If a line is drawn through Lighter Copy or Auto Image Density it means that...

Page 114: ...witch 2 Turn ON DIP101 5 and 8 on the main board 3 Turn ON the main switch The Call Service Misfeed Toner Collection Bottle and Add Toner indicators will blink This is to confirm that the correct mode...

Page 115: ...ID Setting 1 Lead Edge Erase Function 1 All Indicators ON Press the Copy Exit Way key to turn the indicators ON Press C S to turn them OFF 2 Auto Reset Time 0 2 minutes 1 1 minute 2 3 minutes 3 4 minu...

Page 116: ...Sheet Feeder 1 Manual Feed 7 Default Paper Exit 0 Upper Exit 1 Lower Exit 1 If a line is drawn through Lighter Copy or Auto Image Density it means that the indicator is off Lighter Copy Auto Image De...

Page 117: ...seconds E8 Immediate Exposure lamp thermistor short TH3 resistance 2 4 or less for 20 seconds E9 Immediate Fusing overheat Hot roller temperature 200o C or more EA Immediate Ready failure Ready condit...

Page 118: ...g edge OFF check 020 Original is not fed within 6 seconds after the lead edge is detected 022 Original is too small Minimum B5 lengthwise 024 Original is under the original set detector when the origi...

Page 119: ...feeder does not reach the 2nd feed detector within 4 seconds 017 Registration sensor leading edge OFF check 018 Registration sensor leading edge ON check 019 2nd feed detector leading edge ON check 0...

Page 120: ...wer exit sensor trailing edge OFF check 038 Exit sensor leading edge OFF check 039 Exit sensor leading edge ON check 040 Registration sensor trailing edge OFF check 042 Transport sensor leading edge O...

Page 121: ...1 Digital Multimeter 54209507 BECKMAN RMS3030 2 Deluxe Test Lead 54209508 BECKMAN DL241 Accessory Kit 3 Grease Mobil 54479078 400 g can Temp 78 4 Current Measuring A0239520 Drum 5 DG Gauge A0239101 6...

Page 122: ...SECTION 5 REPLACEMENT AND ADJUSTMENT...

Page 123: ...riginal feed unit Remove the top left cover C 4 screws 3 Front Left Cover Open the original feed unit middle unit and toner cartridge cover Remove the middle left cover Remove the front left cover D 6...

Page 124: ...ed unit Remove the top right cover C 4 screws 3 Front Right Cover Open the original feed unit middle unit and toner cartridge cover Remove the middle right cover Remove the front right cover D 6 screw...

Page 125: ...Remove the light sensor unit B 1 screw and discon nect the plug of the ID pattern shutter unit C 2 screws 3 Remove the two shoulder screws D securing the fi ber optics unit E 4 Rotate the fiber op tic...

Page 126: ...s 4 screws 4 Remove the left lamp socket A 2 screws and discon nect the 2p B and 3p C connectors 5 Remove the left lamp holder D 2 screws 6 Slide the exposure lamp to the left and remove it from the m...

Page 127: ...multimeter leads to TP104 ADS OUT and TP106 GND 4 Close the upper unit and turn on the main switch 5 Press the Lighter key A 6 times to select ID level 6 and press the Lead Edge Erase key twice B to s...

Page 128: ...DC 2 6 0 1V 2 5 LIGHT SENSOR ADJUSTMENT ADJUSTMENT STANDARD Level 2 of a 10 step gray scale should be slightly visible 1 Make several copies 2 Check the background no image area and low contrast image...

Page 129: ...ing the the main board to the right 5 Remove the ground screw A securing the cover plate B then move the cover plate slightly to the right and remove it NOTE Never touch the drum surface with your bar...

Page 130: ...the T S co rona unit and re move the screw fixing the ground wire located on the back side of the T S corona unit Then remove the corona unit from the machine 10 Place the left and right drum holders...

Page 131: ...the cleaning blade 14 Reset the main board 15 Use SP mode 33 ID level 2 erase margin 10 mm and VR104 to adjust the ID sensor output voltage at TP102 to 4 0 1 V NOTE 1 The left and right drum holders...

Page 132: ...ona wire is bent sharply the coating will be damaged If grid wires are bent uneven image density may result 1 Remove the drum 2 Remove the ground lead A and the step screw B se curing the right end of...

Page 133: ...rectly seated in the eight slots in each endblock 7 Slide a sheet of pa per under the grid wires Slide the sheet of paper from one end of the co rona unit to the other while confirm ing that the grid...

Page 134: ...e of measuring more than 1000 volts 5 Connect the voltage lead of a multimeter to the G pin on the C B G power pack and connect the common lead to the machine s frame Ground 6 Set the lead edge erase...

Page 135: ...ge the range on the digital multimeter If it is not the multimeter may be damaged 4 3 1 Preparation 1 Turn off the main switch and remove the following a Pick off pawl unit b Upper registration cover...

Page 136: ...tage using output mode No 61 Press the Auto Image Density key and set the lead edge erase to 15 mm Press the Copy Exit Way key 5 Turn VR101 on the CBG power pack to obtain 1 1 mA 6 Turn off the main s...

Page 137: ...er corona 2 using output mode No 63 5 Turn VR T2 T Sel on the TS power pack to obtain DC 250 5 10 A 4 3 4 Separation Corona ADJUSTMENT STANDARD AC 250 5 A DC 10 1 A 1 Remove the lower rear cover 2 Gen...

Page 138: ...MENT Adjustment Standard 0 6 0 1 mm 1 Remove the expo sure glass expo sure lamp and the fiber optics array unit 2 Remove the original exit guide A 4 screws 3 Remove the seven guide roller sets B two s...

Page 139: ...ate clamp and remove the two cover plates D E 3 screws 5 Remove the front exposure glass holder F 4 screws 6 Measure the doctor gap with the DG gauge G and ad just the gap by turn ing the two screws i...

Page 140: ...place 3 Take out the screw securing the main board B and swing the board open NOTE Mark the original position of the mag net adjusting plate before removing the plate 4 Remove the mag net adjusting p...

Page 141: ...crews 7 Set the PG gauge to 0 75mm and loosen the adjustment screws F G at both ends of the development roller 8 Check the gap at both ends of the roller with the PG gauge Set the gap to the adjustmen...

Page 142: ...t cover and turn on DIP switches 101 7 and 101 8 4 Turn on the main switch and press the Lighter key six times the sixth LED segment from the right of the copy density indica tor will light 5 Set Lead...

Page 143: ...the main board DIP switch 101 8 3 Turn on the main switch 4 Attach the multime ter leads to TP102 Vsg OUT and TP106 GND 5 Press the Lighter key to manually set the image density at level 2 and set Le...

Page 144: ...board DIP switch 101 8 3 Turn on the main switch 4 Attach the multime ter leads to TP103 TDS OUT and TP106 GND 5 Press the Lighter key to manually set the image density at level 4 and set Lead Edge Er...

Page 145: ...the exposure lamp 5 Remove the upper toner supply bracket A 3 screws 6 Disconnect the toner sensor connector and remove the doctor blade Refer to DOCTOR GAP ADJUSTMENT 7 Remove the devel opment motor...

Page 146: ...k spill plates I 1 screw 11 Remove the mixing auger J and the mixing separator casing K 4 screws 12 Peel off the side seal and pull out the development roller 13 After replacing the development roller...

Page 147: ...pment roller See DEVELOPER ROLLER REPLACEMENT 2 Remove the paddle roller bearing A and drive gear B 3 Remove the left and right paddle roller shafts C and D 2 E rings 2 spacers 2 bushings and replace...

Page 148: ...ON 1 Remove the C B G power pack unit A 3 screws 3 bias leads and the development motor unit B 5 screws 2 Remove the toner supply clutch C 2 Allen screws and take it apart 3 Clean each part and apply...

Page 149: ...unit and lay a sheet of A2 paper C inch size un der the developer exit as shown A 2 Activate the lower safety switch 3 Remove the upper registration guide plate B 1 screw 4 Open the devel oper exit co...

Page 150: ...ll pour out onto the paper Af ter about 15 min utes nearly all of the developer will be out of the devel opment unit 7 Press the Clear Stop key C to turn off the main motor and the development motor t...

Page 151: ...and swing open the main board A 1 screw 2 Open the used toner tank cover B 3 Disconnect the toner overflow sensor connector and pull out the tank C 4 Take off the toner collection cap D and pour the u...

Page 152: ...5 Clean the toner overflow sensor E with a blower brush or equiva lent E 6 January 1990 5 30...

Page 153: ...er on the pa per transport sec tion See the illustration 2 Remove the pick off pawl unit regis tration cover and drum See the drum replacement section 3 Press the cleaning blade release lever 4 Pull u...

Page 154: ...7 QUENCHING 7 1 CLEANING THE QUENCHING LAMP 1 Remove the charge corona unit Refer to the charge corona unit replacement proce dure 2 Clean the quench ing lamp with a blower brush 6 January 1990 5 32...

Page 155: ...t horizon tal covers 3 Remove the cool ing fan A 2 screws 4 Remove the press roller plate B 4 screws 5 Remove the 4th press rollers C 7 sets 2 screws each 6 Remove the quenching lamp unit D 4 screws 7...

Page 156: ...over and the left inner cover 2 Remove the paper feed clutch A and the registra tion clutch B 3 Take the clutches apart then clean and lubricate each part NOTE When reassembling the paper feed clutch...

Page 157: ...R REPLACEMENT 1 Remove the middle right cover 2 Remove the upper guide plate 3 Remove the 1st feed detector A and 2nd feed de tector B assem blies 1 screw and 1 connector each 4 Replace the detec tors...

Page 158: ...MENT 1 Remove the middle right cover 2 Remove the regis tration cover A 1 screw 3 Remove the regis tration sensor as sembly B 2 screws then re move the sensor 2 screws 1 con nector 4 Install a new sen...

Page 159: ...plate B 6 screws and the lower registration guide plate C 4 screws 2 Remove the paper feed clutch D 2 Allen screws and the registration clutch E 1 Allen screw 1 connector 3 Remove the collar F 1 Alle...

Page 160: ...4 Remove the collar H 1 Allen screw and bracket I 1 screw then remove and replace the registration roller J 1 E ring 2 bushings 1 spacer H J I 6 January 1990 5 38...

Page 161: ...orizon tal covers 3 Open the toner col lection tank cover and take out the toner collection tank 4 Remove the bot tom right cover A 5 Remove the pin B securing the main board bracket C 6 Take the wire...

Page 162: ...s 9 Loosen the timing belt and remove the bracket B 5 screws 10 Open the exit guide unit and re move the left and right slider plate screws 1 screw for each plate 11 Disconnect the two exit guide unit...

Page 163: ...curing the paper exit unit 13 Remove the ten sion sprocket C and the paper exit unit drive chain D 14 Disconnect the pa per exit unit con nectors and remove the paper exit unit E See the illustration...

Page 164: ...cover A and disconnect the fusing lamp connector B 16 Disconnect the two connectors C and remove screw D 17 Remove screw F close the middle unit and remove screw E 18 Pull out the fusing unit D B F E...

Page 165: ...then remove the lamp holder B 1 screw 3 Remove the lamp holder C 2 screws wire clamp D 1 screw and har ness cover E 2 screws 4 Slide out the fusing lamp F 5 Carefully slide in the new fusing lamp lead...

Page 166: ...guide plate B 4 screws 4 Remove the left and right pressure springs C D 5 Remove the en trance guide plate E 2 screws 6 Remove two C rings F the gear G two bushings H and two bear ings I 7 Slide the...

Page 167: ...t 2 Remove the fusing unit top cover 3 Take the thermo fuse wire out from the clamps 6 clamps 1 screw each 4 Remove the ther mofuse holder A 1 screw 5 Remove the ther mofuse terminal B 1 screw and rep...

Page 168: ...Remove the fusing unit top cover 4 Take the hot roller thermistor wire out from the clamps 2 clamps 1 screw each and remove the hot roller ther mistor holder A 2 screws then replace the ther mistor 5...

Page 169: ...fusing roller and the pres sure roller A 3 Slide the pressure roller shaft B out from the pressure roller 4 Loosen the four Al len screws on each of the adjust ment bearings C D 5 Set the bearings in...

Page 170: ...THE CLEANING ROLLER 1 Remove the fusing unit 2 Remove the clean ing roller A to gether with its guide plate 4 screws 3 Wipe toner from the cleaning roller with a cloth and a cleaning solution A 6 Janu...

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