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Ricoh FW830, Service Manual, Page: 100 / 227

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Ricoh FW830 Service Manual Download Page 100

3. SERVICE TOOLS  

3.1

SERVICE PROGRAM MODE

The service program (SP) mode is used to check electrical data and change
modes or adjustment values.

3.1.1 Access Procedure

  1. Turn on the main switch.

  2. Turn on DPS101-8 on the main board.

NOTE: The Call Service [A] and Add Toner [B] indicators will blink. This is

to confirm that the correct mode has been selected.

ON

1

2

3

4

5

6

7

8

[D]

[H]

[C]

[G]

[J]

[I]

[E]

[F]

[B]

[A]

SERVICE TOOLS  

31 December 1992

4-14

Summary of Contents for FW830

Page 1: ...le the main switch is turned on keep hands away from electrified or mechanically driven components 5 The inside and the metal parts of the fusing unit become extremely hot while the copier is operatin...

Page 2: ...battery Used batteries must be handled in accordance with local regulations SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Do not incinerate the toner cartridge or the used toner Toner dust may ignite sud...

Page 3: ...SECTION 1 OVERALL MACHINE INFORMATION...

Page 4: ...to no auto reset Photoconductor 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 Expo...

Page 5: ...ilicone rubber lower rollers 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 15 A 220 V 50 Hz 7 A 240 V 50 Hz...

Page 6: ...s copier can be equipped with optional equipment as show above 1 Copier A098 2 Sheet Feeder A453 3 Roll Feeder A454 and Connector A384 4 Roll Feeder A454 and Sheet Feeder A453 3 2 4 1 31 December 1992...

Page 7: ...e 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 The char...

Page 8: ...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 Separation A stro...

Page 9: ...4 MECHANICAL COMPONENT LAYOUT 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5 9 3 2 1 36 35 33 32 31 30 29 28 27 26 4 34 MECHANICAL COMPONENT LAYOUT 31 December 1992 1 6...

Page 10: ...r 14 Switch Back Gate 15 Hot Roller 16 Upper Exit Rollers 17 Exit Gate 18 Exit Rollers 19 Pressure Roller 20 Transport Belt 21 Pick off Pawls 22 T S Corona Unit 23 Paper Registration Rollers 24 Lower...

Page 11: ...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 Chain 22 Drum Drive Belt 23 Feed Fusing Dri...

Page 12: ...rd feed mechanism 52 Registration Drives the registration rollers 50 Original Re verse Feed Drives the original reverse feed mechanism 8 Solenoids Toner Supply Turns on to supply toner to the developm...

Page 13: ...64 Rear Feeder Detects when the rear feeder table is opened 21 Sensors Image Density Detects the image density of the test pattern on the drum 33 Toner Density Detects the density of toner in the dev...

Page 14: ...16 Lower Exit Detects jams through the lower exit guides 18 Printed Circuit Boards Main Controls all copier functions both directly and through other PCBs 63 DC Power Supply Provides dc power for all...

Page 15: ...Monitors the fluorescent lamp s temperature 44 Thermofuses Fusing Protects against fusing overheat Two thermofuses in parallel 59 Exposure Lamp Protects against exposure lamp overheat 44 Heaters Expo...

Page 16: ...Name Function Index No Vacuum Fan Motor Capacitor Motor start capacitor 70 31 December 1992 ELECTRICAL COMPONENT DESCRIPTIONS 1 13...

Page 17: ...7 ORIGINAL AND PAPER PATH Repeating Copy Except for A0 E A1 D Lengthwise B A A Upper Copy Exit B Lower Copy Exit ORIGINAL AND PAPER PATH 31 December 1992 1 14...

Page 18: ...A0 E A1 D Lengthwise Switching Back Switching Back 31 December 1992 ORIGINAL AND PAPER PATH 1 15...

Page 19: ...SECTION 2 DETAILED SECTION DESCRIPTIONS...

Page 20: ...rface dissipates when the drum is exposed to light The conductivity of the OPC drum is greatly enhanced by exposure to light Dissipating an amount of charge in direct proportion to the intensity of th...

Page 21: ...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 presses...

Page 22: ...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 wir...

Page 23: ...pplied 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 adjusted using ser...

Page 24: ...as the drum s peripheral velocity The platen roller E presses the original F flat against the exposure glass G just above the fiber optic array This ensures that the image is properly focused The ori...

Page 25: ...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 and the...

Page 26: ...F original registration G and rear original feed H rollers turn backwards and the switch back gate I is lifted to the up position The original is transported to the machines rear side At the appropri...

Page 27: ...n rollers rotate in the original forward direction When the original reverse feed clutch F is energized the rear original feed roller shaft starts turning the original drive belt 3 backwards from the...

Page 28: ...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 of the...

Page 29: ...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 intensity...

Page 30: ...23 1 59 11 1 10 24 1 64 12 1 15 25 1 69 13 1 18 26 1 74 3 5 1 Manual ID Control When in manual image density mode the user can select one of 26 manual ID levels For each level the intensity of the li...

Page 31: ...ge 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 dependin...

Page 32: ...emitting light from ADS 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 origin...

Page 33: ...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 C GN...

Page 34: ...e 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 lamp...

Page 35: ...07 B3 to LOW The copier then stops operation the Call Service Indicator wrench mark lights and E8 are alternately displayed in the Copy Counter If the exposure lamp thermistor circuit becomes open the...

Page 36: ...itively charged toner In this way the latent image is developed Negative bias is applied to the development roller to prevent toner from being attracted to non image areas on the drum that may have re...

Page 37: ...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 toner agi...

Page 38: ...octor 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 develop...

Page 39: ...opy every 1220 mm If the test pattern image density 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 on...

Page 40: ...lculated 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 Toner...

Page 41: ...er density will be checked every 610 mm regardless of Vsp Vsg The toner supply amount can be adjusted using service program mode 17 Using service program 34 Vsp Vsg and Vsp Vsg can be displayed in the...

Page 42: ...V toner supply is prohibited Second it checks toner density if an original larger than 1220 mm is copied Third it takes over toner density control completely if the ID sensor becomes abnormal Vsp 2 5...

Page 43: ...an 1 6 V or more than 4 7 V Toner Density Sensor Output Vts Toner Density Condition Vts 4 7 Abnormal Service Call Ed 4 7 Vts 3 8 Low Toner density sensor control Toner is supplied 3 8 Vts 2 4 Normal I...

Page 44: ...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 positively charged toner from b...

Page 45: ...ection 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 1 0...

Page 46: ...ixture is broken in The following table shows this correction Notice that the correction depends on the average Vsp Vsg ratio as measured during initial conditioning as well as on the developer counte...

Page 47: ...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 develop...

Page 48: ...ve 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 drum by the positive c...

Page 49: ...d 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 sensor the pick off sol...

Page 50: ...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 longer than 3 seconds the CPU uses both T T...

Page 51: ...nto 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 appl...

Page 52: ...inals 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 and ac...

Page 53: ...ays 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 det...

Page 54: ...e as the 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...

Page 55: ...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 G The manual feed solenoi...

Page 56: ...ed 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 and the registration roller G...

Page 57: ...cuum 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 rollers ar...

Page 58: ...levers at the ends of the fusing unit The fusing lamp C which is located at the hot roller axis turns on and off to maintain the operating temperature The temperature control circuit on the main board...

Page 59: ...e exit gate directs the copy paper down through the lower copy exit path If the exit gate solenoid is off the paper goes through the upper copy exit path The exit direction is selected using the Copy...

Page 60: ...ure 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 sprockets E and th...

Page 61: ...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 the main moto...

Page 62: ...ve 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 volts is applied at CN301 5 RA3...

Page 63: ...C107 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 then turns...

Page 64: ...e operating temperature of the hot roller 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 thermis...

Page 65: ...ature while copying the copier stops and the fusing lamp turns on until the temperatures return to the range of high mode The original will automatically feed out normal mode By changing SP mode 96 th...

Page 66: ...k 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 no pu...

Page 67: ...etermine if a key has been pressed Each KEY line is used to monitor up to five keys on the operation panel A specific scan pulse appears at the appropriate KEY line when a key on the operation panel i...

Page 68: ...SECTION 3 INSTALLATION...

Page 69: ...ine as 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...

Page 70: ...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 ENVIRONMENT 31 December 1992 3 2...

Page 71: ...for U S A version 220 V 230 V 240 V 50 Hz More than 7 A for European version 2 Permissible Voltage Fluctuation 10 3 Do not set anything on the power cord NOTE a Make sure the plug is firmly inserted i...

Page 72: ...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 12 pcs 9 Pan head Screw M4 x 8 2 pcs 10 Flat head Screw M4 x 6 3 pcs 11 Fixing Plate 1 pc 12 Co...

Page 73: ...sheets large A and small B 2 Install the copier on the table Align the 2 pins C and 2 holes D Fix the rear side 1 screw and spacer each and the front right side 2 bolts 0 3 0 3 0 3 0 3 B A C D 31 Dec...

Page 74: ...g tape and accessories 4 Open the original feed unit A and remove the two spacers B Remove the protective sheet from the exposure glass 5 Remove the right middle cover C 4 screws A B B C INSTALLATION...

Page 75: ...Remove the plate B 4 screws fixing the right portion of the upper unit to the lower unit Keep two screws for mounting the fixing plate later 8 Remove the left middle cover C 4 screws C B C 31 Decembe...

Page 76: ...the middle unit could open suddenly 9 Remove the screw A fixing the left portion of the upper unit to the lower unit 10 Lift up the handle B and open the middle unit C 11 Install the fixing plate D 2...

Page 77: ...the pick off pawl unit B 2 connectors C 2 knob screws D and 2 positioning pins 14 Remove the drum protection sheet E by turning the main motor F counterclockwise Make sure that no tape is left on the...

Page 78: ...iginal feed unit 16 Open the toner cartridge cover B and place a level C in the space between the cartridge cover and the developer entrance Adjust the level of the machine by turning the bolts on the...

Page 79: ...s shown b Connect the input line C to the appropriate voltage 230 V or 240 V c Reinstall the lower registration guide plate 19 Turn on DIP SW 101 7 and 8 on the main board C Then plug in the power cor...

Page 80: ...the plus key E once to set the trailing margin indicator to 01 22 Press the Copy Exit Way key F to turn on the development motor Press the Copy Exit Way key again after 2 or 3 seconds to turn the moto...

Page 81: ...26 Remove the sealing tape A on the cartridge and turn the knob B clockwise until it stops 27 Lift up the release handle C and open the middle unit B A C 31 December 1992 INSTALLATION PROCEDURE 3 13...

Page 82: ...e bracket Use 1 flat head screw and 3 pan head screws for the right inner cover 29 Install the left inner cover C onto the lower unit 2 flat head and 5 pan head screws 30 Install the left middle cover...

Page 83: ...support C gear D and spring E as shown 4 bushings 1 Allen screw F 35 Install the 2 plastic caps G 36 Check the operation If the exit support lever movement seems heavy lower the fixing position of th...

Page 84: ...37 Stick 4 Velcro seals A to the copier and table as shown Set the 2 copy guide mylar strips B as shown A B A B A A B 0 3 0 3 0 3 0 3 INSTALLATION PROCEDURE 31 December 1992 3 16...

Page 85: ...counter indicator C to 01 using the plus key Then press the Copy Exit Way key D Turn off DIP SW101 8 to start initial conditioning Initial conditioning will start and stop automatically when it is com...

Page 86: ...SECTION 4 SERVICE TABLES...

Page 87: ...C Water or alcohol 4 Platen roller C C C C C C Water or alcohol 5 Press rollers C C Water or alcohol 6 White plate C C C C C C Water or alcohol 7 Auto image density sensor C C C C C Blower brush 8 Or...

Page 88: ...na wires C C C C C C Blower brush or if clean with a dry cloth don t expand the corona wires Replace at 20 K A1 sideways D size 2 Wire cleaner pads Replace at 20 K A1 sideways D size 3 Grid wires C C...

Page 89: ...______________ EM 3 6km 7 2km 10 8km 14 4km 18km Notes 6k 12k 18k 24k 30k A1 sideways D size 1 Manual feed rollers C C C C C C Water 2 Manual feed table C C C C C C Water 3 Registration rollers C C C...

Page 90: ...ot roller strippers C Suitable solvent 5 Fusing exit guide plate Suitable solvent if necessary I Others_______________________________________________________ EM 3 6km 7 2km 10 8km 14 4km 18km Notes 6...

Page 91: ...lean with a damp cloth if necessary 6 Spring clutch L Mobil Temp 78 7 Teflon tape 2 tapes R K Roll Feeder __________________________________________________ EM 3 6km 7 2km 10 8km 14 4km 18km Notes 6k...

Page 92: ...OTE After removing the drum wrap it in clean sheets of paper to protect it 1 Clean the corona wires and grid wires with a blower brush or dry cloth Note When using dry cloth don t expand the corona wi...

Page 93: ...al 3 Clean the cleaning blade with your finger Inspect the side seals 5 Cleaning Unit every 6 K Around Drum every 12 K 6 Development Unit every 6 K Around Drum every 20 K Replace the cleaning blade ev...

Page 94: ...t and transport guide plate with water 1 Clean the thermistors 2 Clean the hot roller stripper 120 K 7 Paper feed every 6 K 8 Transport every 6 K Lubricate the paper feed clutch every 18 K 18 K 9 Fusi...

Page 95: ...ring clutch Replace the friction pad and teflon tape 2 pcs Replace the feed roller and bottom plate pad Clean the feed roller and exit roller with water 10 Others every 6 K 11 Sheet Feeder every 6 K O...

Page 96: ...Adjust the light sensor voltage by turning VR102 on the main board 3 Adjust the ADS reference voltage by SP 37 4 Adjust the Vsg by SP 33 13 Roll Feeder Connector every 6 K Roll Feeder Connector every...

Page 97: ...image density sensor ADS Adjusts the voltage to 3 0 0 1 volts by VR103 TP105 Light sensor Adjusts the voltage by VR102 TP106 GND TP107 Vcc 5 volts TP108 VAA 24 volts 2 2 VARIABLE RESISTORS Main Board...

Page 98: ...voltage Transfer Separation Power Pack NUMBER FUNCTION T1 Adjusts low normal transfer corona current T Trig T2 Adjusts high transfer corona current T Sel D1 Adjusts ac current of separation corona D2...

Page 99: ...al Sends the reset signal to the main CPU Increments the total counter every meter of paper Increments the total counter 100 inches of paper Refer to the Service Tools section for details Note 1 DPS10...

Page 100: ...e modes or adjustment values 3 1 1 Access Procedure 1 Turn on the main switch 2 Turn on DPS101 8 on the main board NOTE The Call Service A and Add Toner B indicators will blink This is to confirm that...

Page 101: ...will sound three times after a value or mode is entered 2 For some SP modes you only need to press the Copy Exit Way key directly without pressing the Plus or Minus key These SP modes are marked in t...

Page 102: ...ll blink This is to confirm that the correct mode has been selected 2 Follow the steps 3 to 5 of the SP mode access procedure 3 To leave this mode turn off the main switch Mode No Function Data No Lea...

Page 103: ...Normal 1 Initial conditioning Initial conditioning must be done whenever new developer is installed The CPU monitors Vsg and Vsp for the developer counter correction during the initial conditioning T...

Page 104: ...Sheet Feeder Roll Feeder 1 Copier Roll Feeder Roll Feeder Connector 2 Copier Sheet Feeder 3 Copier only This SP mode must be done whenever pheripheral is installed 15 01 05 Copy Paper Original Waiting...

Page 105: ...rformed every 1220 mm length of originals or 610 mm length of originals 0 1220 mm originals 1 610 mm originals If low image density occurs in the toner near end condition change the data to 1 22 02 02...

Page 106: ...0 5 mm 7 0 75 mm 8 1 0 mm 27 02 07 Rough Registration Adjustment Manual Feed and Sheet Feeder Adjusts registration for the manual feed and sheet feeder 1 mm step 0 0 mm 1 5 mm 2 4 mm 3 3 mm 4 2 mm 5...

Page 107: ...e roller temperature is less than 50 C LLL is displayed If the hot roller temperature is more than 210 C or pressure roller temperature is more than 180 C HHH is displayed 33 03 03 Vsg Adjustment Adju...

Page 108: ...S voltage for white plate Adjusts ADS voltage for the white plate to 3 0 0 1 volts using VR103 on the main board After the adjustment is finished press the Copy Exit Way key 38 03 08 ADS Voltage Displ...

Page 109: ...Misfeeds Lower Transport Section Displays the number of original misfeeds in the lower transport section 4 digits J Number of original misfeeds To stop the display press the Copy Exit Way key 46 04 06...

Page 110: ...stop the display press the Copy Exit Way key 53 05 03 Paper Misfeeds Pick off Displays the number of paper misfeeds in the pick off section 4 digits J Number of paper misfeeds To stop the display pre...

Page 111: ...or does not light and copying is possible To stop the display press the Copy Exit Way key 61 06 01 ID Sensor Abnormal Display Displays when the Vsg is less than 2 5 volts or Vsp is more than 2 5 volts...

Page 112: ...f copies To stop the display press the Copy Exit Way key 67 06 07 Total Length Counter Meters Displays the total meters of copies made 6 digits Meters of copies meter number To stop the display press...

Page 113: ...0 mm 79 07 09 Rough Registration Adjustment Roll Feeder Adjusts registration of the roll feeder 1 mm step 0 0 mm 1 5 mm 2 4 mm 3 3 mm 4 2 mm 5 1 mm 6 1 mm 7 2 mm 8 3 mm 9 4 mm 80 08 00 Cut Error Corre...

Page 114: ...ll feeder is installed 84 08 04 Cut Error Correction 2 Preset Cut 1189 mm Correct cut error for preset cut 1189 mm Input the number according to the decal on the roll feeder right cover 10 mm step 0 2...

Page 115: ...5 0 25 mm 6 0 5 mm 7 0 75 mm 8 1 0 mm 89 08 09 Rough Cut Length Adjustment Preset Cut Mode Adjusts the cut length of the preset cut mode 1 mm step 0 0 mm 1 5 mm 2 4 mm 3 3 mm 4 2 mm 5 1 mm 6 1 mm 7 2...

Page 116: ...when the roll feeder is installed 94 09 04 Cut Error Correction 2 Synchro Cut 1189 mm Correct cut error for synchro cut 1189 mm Input the number according to the decal on the roll feeder right cover...

Page 117: ...ches etc from the operation panel 3 2 1 Access Procedure 1 Turn on the main switch 2 Turn on DPS101 6 and 101 8 on the main board NOTE The Call Service A and Misfeed B indicators will blink This is to...

Page 118: ...icator I or Lower Exit indicator J 4 Input a new input check number as follows When changing to another mode number a Press the Margin key A number will blink in the Leading Margin indicator Enter the...

Page 119: ...nsor 14 01 04 Upper Exit Sensor 15 01 05 Lower Exit Sensor 16 01 06 Paper End Sensor Sheet Feeder Paper detected Paper end 17 01 07 Sheet Feeder Set Switch Sheet feeder set Sheet feeder not set 18 01...

Page 120: ...t Indicator Lower Exit Indicator 30 03 00 Toner Overflow Sensor Used toner overflow Used toner not overflowed 31 03 01 Exposure Lamp Heater ON OFF 32 03 02 Exposure Lamp Thermistor Open Open Not open...

Page 121: ...the operation panel 3 3 1 Access Procedure 1 Turn on the main switch 2 Turn on DPS101 7 and 101 8 on the main board NOTE The Call Service A and Used Toner Tank B indicators will blink This is to conf...

Page 122: ...splayed in the Copy Counter indicator J When it is OFF 0 is displayed in the Copy Counter indicator 5 Input a new output check number as follows When changing to another number a Press the Margin key...

Page 123: ...Pattern Shutter Solenoid 12 01 02 Toner Supply Solenoid 13 01 03 Sheet Feeder Solenoid 1 14 01 04 Sheet Feeder Solenoid 2 15 01 05 Fusing Lamp 16 01 06 ID Sensor LED 17 01 07 Total Counter 18 01 08 AD...

Page 124: ...t 1 60 volts 2 60 volts 3 80 volts 4 100 volts 5 120 volts 6 140 volts 7 160 volts 8 180 volts 9 200 volts Copy Counter Indicator Dev Bias Voltage 0 220 volts 1 240 volts 2 260 volts 3 280 volts 4 300...

Page 125: ...80 volts 2 400 volts 3 420 volts 4 440 volts 5 460 volts 6 480 volts 7 500 volts 8 520 volts 9 540 volts Copy Counter Indicator Grid Voltage 0 560 volts 1 600 volts 2 620 volts 3 640 volts 4 660 volts...

Page 126: ...No Leading Margin Indicator Trailing Margin indicator 38 03 08 Paper Feed Motor Roll Feeder 39 03 09 Cutter Motor Roll Feeder 74 07 04 Original Reverse Feed Clutch 75 07 05 Switch Back Gate Solenoid...

Page 127: ...Copy Exit Way key to clear 5 Turn off DPS101 5 and 101 8 3 4 2 All Memory Clear Procedure CAUTION All memory clear mode clears all the correction data for process control and software counters and ret...

Page 128: ...heripherals are installed 2 SP 80 SP 85 SP 90 SP 95 Cut Error Corrections If the roll feeder is installed 3 SP 5 Initial Conditioning 4 SP 35 Toner Density Sensor Adjustment 5 SP 33 Vsg Adjustment 6 S...

Page 129: ...urns on 16 2nd original transport sensor ON check SP43 Upper transport section 17 2nd original transport sensor leading edge OFF check 18 Original registration sensor ON check SP45 Lower transport sec...

Page 130: ...inal table 28 The original registration sensor stays on when the original exit sensor trailing edge OFF check When the original is fed from the rear original table 29 Original registration sensor ON c...

Page 131: ...et feeder 17 Registration sensor leading edge OFF check SP52 Manual feed and registration 18 Registration sensor ON check 20 2nd feed sensor leading edge OFF check 21 Original is not set within 10 sec...

Page 132: ...railing edge OFF check 37 Lower exit sensor trailing edge OFF check 38 Fusing exit sensor leading edge OFF check SP53 Pick off 39 Fusing exit sensor ON check 40 Registration sensor trailing edge OFF c...

Page 133: ...ECKMAN RMS3030 2 Deluxe Test Lead Accessory Kit 54209508 BECKMAN DL241 3 Grease Mobil Temp 78 54479078 400 g can 4 Current Measuring Drum A0239520 5 0 35 mm DG Gauge A0989105 6 0 5 mm DG Gauge A098910...

Page 134: ...m surface 5 Store the drum in a cool dry place away from heat 6 Take care not to scratch the drum as the drum layer is thin and is easily damaged 7 Never expose the drum to corrosive gases such as amm...

Page 135: ...er or a solvent 2 Do not touch the corona wire and the grid wires with oily hands Oil stains may cause uneven image density on copies 3 Make sure that the corona wire is correctly positioned between t...

Page 136: ...ons 6 5 TONER SUPPLY 1 Clean the image density sensor with a dry cloth or a blower brush 2 Vsg adjustment is required in the following cases a When the image density sensor is replaced b When the main...

Page 137: ...nal feed rollers original registration rollers platen roller and press rollers with bare hands 2 Clean the white plate with water or alcohol 3 Clean the auto image density sensor with a blower brush 6...

Page 138: ...rn on the DPS101 5 and 101 8 on the main board NOTE The Call Service Misfeed Used Toner Tank and Add Toner indicators will blink This is to confirm that the correct mode has been selected 3 Press the...

Page 139: ...ent 7 Light Sensor Adjustment by using VR102 on the main board 8 SP 26 or SP 27 Registration Adjustment Manual Feed and Sheet Feeder 9 SP 78 or SP 79 Registration Adjustment Roll Feeder If the roll fe...

Page 140: ...SECTION 5 REPLACEMENT AND ADJUSTMENT...

Page 141: ...over D 2 screws loosen 2 screws E 1 1 3 Front Left Cover 1 Open the original feed unit middle unit F and toner cartridge cover G 2 Remove the middle left cover 2 screws loosen 2 screws 3 Remove the fr...

Page 142: ...E 1 2 3 Front Right Cover 1 Open the original feed unit middle unit F and toner cartridge cover G 2 Remove the middle right cover 2 screws loosen 2 screws 3 Remove the front right cover H 4 screws lo...

Page 143: ...Remove the two exposure glass holders A 2 hexagon head screws each 3 Remove the exposure glass B NOTE When reinstalling the exposure glass make sure that the beveled edge C of the exposure glass must...

Page 144: ...two shoulder screws B and washers C securing the fiber optics unit D 4 Rotate the fiber optics unit forward and lift it out of the machine 5 Remove the pattern shutter solenoid unit E from the fiber o...

Page 145: ...ver Removal 3 Close the middle unit 4 Remove the exposure glass See Exposure Glass Removal 5 Remove the left lamp socket bracket A 1 screw and 1 shoulder screw 6 Disconnect the 2P B and 3P C connector...

Page 146: ...Do not touch the aperture on the exposure lamp b Make sure that the aperture faces up and to the rear and that the heater faces down and to the front c Make sure that the right lamp terminal fits int...

Page 147: ...the pick off pawl unit B with ID sensor C 2 knob screws and 2 connectors 3 Remove the middle right cover See Middle Right Cover Removal 4 Open the main board bracket 1 screw 5 Remove the ground screw...

Page 148: ...h your right hand NOTE Never touch the drum surface with your bare hands Use a sheet of paper between your hand and the drum to avoid contact 8 Remove and hold the drum with your hand NOTE When removi...

Page 149: ...r D and separation E connectors 3 Lift the T S corona unit F and disconnect the ground wire connector G 4 Remove the T S corona unit 5 Place the left and right drum holders on the main frame as shown...

Page 150: ...s NOTE To avoid drum damage do not open the middle unit before tightening the drum lock knob 8 Open the middle unit 9 Reinstall the T S corona unit G 2 connectors and 1 ground wire connector NOTE When...

Page 151: ...rted in the two holes H of the pick off pawl unit 12 Pull the cleaning unit release lever to the front side until it locks 13 Remove the drum protective sheet 14 Close the main board bracket 1 screw a...

Page 152: ...prevent the drum from being exposed to light 2 Disconnect the ground lead A and remove the shoulder screw B securing the right charge corona cover C 3 Remove the right charge corona cover 4 Move the...

Page 153: ...wire H NOTE 1 Handle the new corona wire by the ends only Oil from your hands may cause uneven charge on the drum 2 Do not expand the corona wire 3 Do not rub the corona wire with rough material sand...

Page 154: ...t holes G 2 Make sure that the wires are all straight and not crossed as shown 3 Handle the new wires by the ends only Oil and chemicals from your hands will deteriorate the wires 4 Do not bend the wi...

Page 155: ...1 8 on the main board to enter the output check mode 5 Enter output check No 32 See Output Check Mode Access Procedure 6 Press the Plus key until 5 is displayed in the Copy Counter indicator Then pres...

Page 156: ...ith paper separation incomplete toner transfer or image density c Make sure that the main switch is turned off when you change the range on the digital multimeter If it is not the multimeter may be da...

Page 157: ...ness leads should be positioned as close as possible to the development roller C so that they are not in the way of any corona units 4 Connect the five harness leads D of the current measuring drum to...

Page 158: ...7 and 101 8 on the main board to enter the output check mode 7 Enter output check No 24 See output Check Mode Access Procedure 8 Press the Copy Exit Way key to turn on the charge corona 9 Enter output...

Page 159: ...r cover A 5 screws and upper rear cover B 4 screws 3 Select dc 200 A on the digital multimeter 4 Turn on the main switch 5 Turn on DPS101 7 and 101 8 on the main board to enter the output check mode 6...

Page 160: ...he digital multimeter 11 Turn on the main switch 12 Enter output check No 26 13 Press the Copy Exit Way key to turn on the high transfer corona 14 Adjust the high transfer corona current to 250 5 10 A...

Page 161: ...screws and upper rear cover B 4 screws 3 Select ac 2 mA on the digital multimeter 4 Turn on the main switch 5 Turn on DPS101 7 and 101 8 on the main board to enter the output check mode 6 Enter output...

Page 162: ...multimeter 11 Turn on the main switch 12 Enter output check No 28 13 Press the Copy Exit Way key to turn on the dc current of the separation corona 14 Adjust the dc separation corona current to 10 0 5...

Page 163: ...knob screw 3 Open the middle unit and lay a sheet of A2 paper C size A on the right side of the paper entrance section as shown 4 Remove the cover plate B 1 ground screw 5 Activate the lower safety sw...

Page 164: ...fter about 15 minutes nearly all of the developer will be out of the development unit NOTE To remove all the developer lift the left side C of the copier as shown 11 Press the Copy Exit Way key to tur...

Page 165: ...the main switch 3 Turn on DPS 101 8 on the main board to enter the SP mode 4 Select SP 35 See Service Program Mode Access Procedure and press the Copy Exit Way key 5 Adjust the toner density sensor vo...

Page 166: ...3 DEVELOPMENT FILTER REMOVAL 1 Open the middle unit 2 Remove the middle right cover 3 Open the main board bracket 1 screw 4 Remove the development filter A 1 screw A DEVELOPMENT 31 December 1992 5 26...

Page 167: ...ight or left If yes proceed with the following steps 4 Adjust and correct the machine level 5 Remove the original exit guide A 2 screws 6 Turn the left B and right C eccentric cams clockwise or counte...

Page 168: ...ght cover 6 Remove a screw B and push down the harness bracket C 7 Remove the toner cartridge holder D Right 2 screws Left loosen 1 screw 8 Remove the toner density sensor holder E 2 screws and 1 conn...

Page 169: ...nd 101 8 on the main board to enter the output check mode 5 Enter output check No 29 See Output Check Mode Access Procedure 6 Press the Plus key until 9 is displayed in the Copy Counter indicator Then...

Page 170: ...C B G power pack unit A 4 screws 3 terminals and 4 connectors 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 171: ...ve the developer See Developer Replacement 2 Remove the exposure glass See Exposure Glass Removal 3 Remove the fiber optics array unit See Fiber Optics Array Removal 4 Remove the exposure lamp See Exp...

Page 172: ...Insert the 0 5 mm DG gauge E in the rear position of the doctor gap 13 While pressing down the doctor blade directly between the two gauges tighten the rear screw F 14 Remove the 0 5 mm DG gauge and...

Page 173: ...tment 2 Remove the doctor blade A 2 screws and 1 connector 3 Remove the drum and mount a used drum in its place NOTE During this adjustment the drum will be in contact with the thickness gauge Therefo...

Page 174: ...thickness gauge F between the drum and the development roller Set the gap to the adjustment standard while turning the front G and rear H positioning gears clockwise or counterclockwise and tighten t...

Page 175: ...tics Array Removal 4 Remove the exposure lamp See Exposure Lamp Replacement 5 Open the toner cartridge cover 6 Remove the original exit guide A 2 screws 7 Remove the seven sets of guide rollers B 2 sc...

Page 176: ...ed screws securing the holder 10 Remove the doctor blade B 2 screws and 1 connector 11 Take out the toner cartridge 12 Remove a screw C and push down the harness bracket D 13 Remove the toner cartridg...

Page 177: ...ft cover B and remove the development motor C 5 screws 16 Disconnect the bias terminal D 1 screw 17 Remove the development drive gear E left positioning gear F left positioning plate G and two bearing...

Page 178: ...plate 20 Remove the magnet adjustment plate 2 screws 21 Remove the right positioning gear B 1 screw and 1 spacer 22 Remove a bushing C and E ring D 23 Remove the three back spill plates E 1 screw 24...

Page 179: ...roller A 27 After replacing the development roller put the side seal at the same location on the new roller 28 Adjust the doctor gap and the photoconductor gap See Doctor Gap Adjustment and Photocondu...

Page 180: ...emove the paddle roller bearing A and drive gear B 3 Remove the right C paddle roller shaft 1 E rings 1 spacer 1 bushing and replace the paddle roller D 4 Adjust the doctor gap and photoconductor gap...

Page 181: ...m with paper to prevent the drum from being exposed to light 2 Place a sheet of A1 size D size paper A on the paper transport section 3 Pull up on the plate spring B and remove the cleaning blade C 4...

Page 182: ...Disconnect the toner overflow sensor connector C 4 Turn the toner collection lever D counterclockwise and pull out the used toner tank E 5 Take off the toner collection cap F and pour the used toner...

Page 183: ...7 QUENCHING 7 1 QUENCHING LAMP CLEANING 1 Remove the charge corona unit See Charge Corona Wire Replacement 2 Clean the quenching lamp A with a blower brush B B A 31 December 1992 QUENCHING 5 43...

Page 184: ...ht Horizontal Cover Removal 3 Remove the cooling fan motor A 2 screws and 1 connector 4 Remove the press roller plate B 4 screws 5 Remove the 4th press rollers C 7 sets 2 screws each 6 Remove the quen...

Page 185: ...he middle unit 2 Remove the left inner cover A 7 screws 3 Remove the clutch collar B Loosen 2 allen screws 4 Remove the clutch sleeve C and spring clutch D 5 Clean and lubricate the spring clutch with...

Page 186: ...ews 3 Remove the 1st feed sensor bracket B with the paper stopper solenoid C 2 screws and 2 connectors 4 Remove the 1st feed sensor D from the bracket 5 Remove the 2nd feed sensor bracket E 1 screw an...

Page 187: ...CEMENT 1 Remove the middle right cover 2 Remove the cover plate A 1 screw 3 Remove the registration sensor bracket B 2 screws and 1 connector 4 Remove the sensor C from the bracket 2 screws A B C 31 D...

Page 188: ...Cover Removal 5 Remove the left inner cover See Paper Feed Clutch Lubrication 6 Close the middle unit and original feed unit 7 Remove the used toner tank See Used Toner Removal 8 Remove the upper ozon...

Page 189: ...s E 17 Slide the exit guide unit to the left rear view and take it out from the copier frame 18 Loosen the screw F securing the tension sprocket G and remove the paper exit drive chain H 19 Remove the...

Page 190: ...ear cover C 5 screws and upper rear cover D 4 screws 23 Remove the small left E and right F covers 2 screws each 24 Open the middle unit 25 Loosen the two screws G securing the tension bracket H 26 Re...

Page 191: ...ler gear B 29 Remove the fusing lamp connector C 30 Remove the hot roller thermistor connector D and the pressure roller thermistor connector E 31 Remove the two screws F and G securing the fusing uni...

Page 192: ...rom the left fusing frame 1 screw each 5 Remove the left stopper D 1 screw 6 Remove the harness cover E 2 screws 7 Remove the left lamp holder F 1 screw 8 Remove the lamp connector G 9 Slide out the f...

Page 193: ...e plate B 4 screws 4 Remove the left and right pressure springs C D 5 Remove the entrance guide plate E 2 screws 6 Remove the right stopper F 1 screw 7 Remove two C rings G the gear H two bushings I a...

Page 194: ...4 screws 3 Take the thermofuse harness A out from the clamps B 7 clamps 1 screw each 4 Remove the thermofuse holder C 1 screw 5 Remove the thermofuse terminal D 2 screws 6 Remove the both end connecto...

Page 195: ...rmistor holder B 2 screws 4 Remove the hot roller thermistor C from the holder 2 screws and 1 spring 5 Remove the left and right pressure springs 6 Remove the fusing unit lower cover D with the exit g...

Page 196: ...r and the pressure roller A See Hot Roller Pressure Roller Replacement 3 Slide the pressure roller shaft B out from the pressure roller 4 Loosen the four Allen screws on each of the adjustment bearing...

Page 197: ...if requested by the customer the overall image density can be changed by changing the toner density Normally this should be kept at the normal position factory setting The grid voltage and charge cor...

Page 198: ...cs array Damp cotton and dry soft cloth 2 ID sensor Dry cloth or blower brush 3 Corona wires charge transfer and separation and casing Dry cloth 4 QL PTL Dry cloth or blower brush 3 Remove the middle...

Page 199: ...Perform SP 19 How Change the development bias voltage for image density control by SP 19 Data SP 19 0 1 2 3 4 Change of bias voltage volts 0 40 20 20 40 Image Density Normal Darkest Darker Lighter Lig...

Page 200: ...development bias voltage for the ID sensor pattern by SP 18 10 4 TONER SUPPLY RATIO SELECTION When The factory setting for toner supply amount is not appropriate for the type of original in use Purpos...

Page 201: ...el 1 Turn off the main switch and clean the following parts Item No Section Method 1 Optics exposure glass fiber optics array Damp cotton and dry soft cloth 2 ID sensor Dry cloth or blower brush 3 Cor...

Page 202: ...The voltage reading is displayed on the operation panel 1 Clean the white plate and auto image density sensor 2 Remove the middle right cover 3 Turn on the main switch 4 Turn on DPS101 8 on the main b...

Page 203: ...DJUSTMENT STANDARD 2 6 0 1 V 1 Remove the middle right cover 2 Set the multimeter range to dc 20 V and connect the multimeter leads as shown 3 Turn on the main switch 4 Adjust the voltage by turning V...

Page 204: ...ler start timing by SP 78 or SP 79 1 Adjust the original registration sensor voltage See Step 1 of Registration Adjustment for Manual Feed and Sheet Feeder 2 Make several copies by using the roll feed...

Page 205: ...opies Perform Turn the eccentric cam clockwise or counterclockwise How Change the rear turn guide plate position 1 Make several copies and check the copy image If a skew image occurs proceed with the...

Page 206: ...ide bracket D 8 Turn the eccentric cam E clockwise or counterclockwise 9 Confirm that the copy image is within the adjustment standard A B C D C C E Copy paper Copy image If copy image occurs turn the...

Page 207: ...der unit A and remove the safety switch cover B 2 screws 2 Open the middle unit 3 Remove the right inner cover C and support bracket D 5 screws 4 Open the used toner tank cover E 1 screw 5 Remove the...

Page 208: ...ion 4 Remove the original feed rear cover B 3 screws 5 Remove the original entrance sensor bracket C 2 screws and 1 connector 6 Remove the original entrance sensor D from the bracket 1 screw 7 Remove...

Page 209: ...SECTION 6 TROUBLESHOOTING...

Page 210: ...0 to 2 Is there sufficient toner in the cartridge Yes No Toner supply amount may be low due to toner near end Replace the toner cartridge Toner supply system may not catch up with large black area on...

Page 211: ...ay not be even Adjust the charge corona height and drum current if necessary 1 1 4 Copy Image not Sharp Is image density of solid areas too high Yes No Is the light intensity setting proper Yes No Adj...

Page 212: ...too high Change the ID sensor bias position from 0 to 1 ADS is not adjusted properly Adjust ADS Do dirty backgrounds still occur at lighter exposure setting Yes No Light intensity may be too low Clean...

Page 213: ...ght path Cleaning function may not work properly Check and fix the cleaning unit Toner density in the development unit may be too high Change ID sensor bias position 0 to 1 Does the dirty background a...

Page 214: ...t unit if bands occur at 37 mm intervals Check and fix the development bias leakage Drum scratch if the bands are at 251 mm intervals Clean or replace the drum Is the edge of the dirty background band...

Page 215: ...st light intensity Replace the drum if lines are still visible Dirty exposure glass or cleaning blade damage Clean the exposure glass or replace the cleaning blade 1 2 5 Random Dirty Background Light...

Page 216: ...erly Yes No Charge corona unit may be not set properly Reset charge corona unit Does the transfer corona leak detection LED light Yes No Transfer corona leak Clean transfer corona unit Replace transfe...

Page 217: ...nism causes void area Check and repair the paper feed section 1 3 4 Leading Edge Void Area Do void areas appear only at the paper leading edge Yes Transfer entrance mylar gap is too narrow Adjust tran...

Page 218: ...pen Definition The temperature detected by the hot roller thermistor does not reach 20 C within 2 minutes after the main switch is turned on The resistance of the hot roller thermistor is more than 12...

Page 219: ...oints to check Pressure roller thermistor Main Board CN110 10 2 1 6 SC Code E8 Exposure Lamp Thermistor Short Definition The resistance of the exposure lamp thermistor is less than 2 4 K for 20 sec on...

Page 220: ...he main motor is on Points to check Connection of the pulse generator connector terminal Pulse generator disc turning or not Main board CN112 1 CN112 3 2 1 10 SC Code EC Total Counter Abnormal Definit...

Page 221: ...AC input voltage CN3 1 CN3 2 CN3 4 CN3 5 Main board CN107 A5 for PWM CN102 7 for Light Sensor out 2 1 13 SC Code No Code SP59 Exposure Lamp Thermistor Open Definition The resistance of the exposure la...

Page 222: ...copying is possible These codes can be displayed using SP58 SP59 or SP61 For all other codes the Call Service indicator turns on and the machine stops 2 When the service call conditions E2 E3 E4 E5 E6...

Page 223: ...74 72 73 76 75 79 85 84 83 82 80 81 86 87 88 77 78...

Page 224: ...90 89...

Page 225: ...3 61 62 64 65 66 67 68 69 70 71 58 59 60 49 47 48 50 51 52 53 54 55 56 57 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...

Page 226: ...der 2 73 I12 Paper Pull Out 89 K12 Switches Main 65 A4 Upper Safety 27 A3 Lower Safety 67 A2 Name Index No P to P Location Rear Safety 22 A3 Toner Cover 45 G16 Sheet Feeder Set 64 B9 Rear Feeder 21 I4...

Page 227: ...4 Operation Panel 32 C12 Auto Image Density 15 C7 Main 79 J14 Lamps Exposure 29 C6 Quenching 20 F2 Fusing 53 B5 Pre Transfer PTL 31 G2 Power Packs Charge Bias Grid Power Pack 49 E2 Name Index No P to...

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