Text preview for : Panasonic FP-7818-7824-7830-7835-7845-7850 Service Manual.pdf part of Panasonic Copier Machine
Service Manual
Parts Manual
Plain Paper Copier
FP-7818/7824/7830
FP-7835/7845/7850
Staple Sorter
FA-S620/660
System Console
FA-DS72/82
Back to : Panasonic FP-7818-7824-78 | Home
ORDER NO. OED9909380B8
FP-7818/7824/7830/7835/7845/7850 Service Manual
Service Manual Parts Manual
Plain Paper Copier
FP-7818/7824/7830 FP-7835/7845/7850 Staple Sorter FA-S620/660 System Console FA-DS72/82
© 1999 Matsushita Graphic Communication Systems, Inc. All rights reserved. Unauthorized copying and distribution is a violation of law.
WARNING
This service information is designed for experienced repair technicians only and is not designed for use by the general public. It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product. Products powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to service or repair the product or products dealt with in this service information by anyone else could result serious injury or death.
For U.S.A
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment on a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his/her own expense. Any unauthorized changes or modifications to this equipment would void the users authority to operate this device.
For U.S.A
This manual was developed and is supplied to authorized servicing dealers by Panasonic Document Imaging Co. for the sole purpose of providing information necessary for the equipment's proper support. It is intended that this information be confidential and may not reproduced without prior written consent from Panasonic Document imaging Co. Panasonic Document imaging Co. reserves the right to change any information enclosed herein without prior notification. This manual was developed and is supplied to authorized servicing dealers by Panasonic Co. for the sole purpose of providing information necessary for the equipment's proper support. It is intended that this information be confidential and may not be reproduced without prior written consent from Panasonic Co. Panasonic Co. reserves the right to change any information enclosed herein without prior notification.
This manual dose not contain descriptions of PCB Connector and Signal Information and Sub Assemblies Operation which are discribed and unchanged in the FP-7718/7722/7728/7735/7742/7750 service manual. For those items not covered in this manual, please refer to the FP-7718/7722/7728/7735/7742/7750 service manual or PCB repaire manual.
Contents / Index
Introduction Unpacking/ Installation Troubleshooting Preventive Maintenance Sub Assemblies Control Functions I. Introduction 1.1 Specification ..................................................................................... 1-1 1.2 Features ............................................................................................ 1-3 1.3 System Configuration ....................................................................... 1-4 1.4 Operation .......................................................................................... 1-6 (1) Special Effects Panel (FP-7818/7824/7830/7835) ...................... 1-7 (2) Communications Monitor (FP-7818/7824/7830/7835) ................ 1-8 1.5 Component Location ......................................................................... 1-9 (1) Inner view .................................................................................. 1-10 (2) Fan/Motor Location ................................................................... 1-11 (3) Sensor Location ........................................................................ 1-12 (4) Solenoid/Clutch/Discharge lamp Location ................................ 1-13 (5) PCB Location ............................................................................ 1-13 1.6 Copy Process ................................................................................. 1-14 1.7 Precautions on Set Up .................................................................... 1-15 1.8 Precautions with Consumables ...................................................... 1-16 II. New Function 2.1 Image Control Qualitative Reasoning Based Adaptive Controller ......... 2-1 2.2 Toner Density Control ....................................................................... 2-3 2.3 Trouble Avoidance Mechanism ........................................................ 2-5 2.4 Toner Recycling System ................................................................... 2-7 2.5 Re-try Control for Paper Misfeed ...................................................... 2-8 III. Sub Assemblies 3.1 Main Drive ......................................................................................... 3-1 (1) Detecting sheet bypass paper size ............................................. 3-2 (2) Developing .................................................................................. 3-3 (3) Supplying toner ........................................................................... 3-4 (4) Toner level detection ................................................................... 3-5 (5) Temperature control .................................................................... 3-6 (6) Automatic detection of original paper size .................................. 3-7 (7) Adjusting quantity of light of AE sensor ...................................... 3-7
i
IV. Preventive Maintenance 4.1 Precautions for Periodic Maintenance Service ................................. 4-1 4.2 Maintenance chart ............................................................................ 4-2 4.3 Cleaning Method ............................................................................... 4-4 4.4 Disassembly and Re-assembly ........................................................ 4-7 (1) Multi-feed bypass ........................................................................ 4-8 (2) Paper feed unit .......................................................................... 4-11 (3) Developer unit ........................................................................... 4-14 (4) Fuser unit .................................................................................. 4-19 (5) Optics unit ................................................................................. 4-24 (6) Automatic duplex unit (ADU ) .................................................... 4-32 (7) Main Body ................................................................................. 4-35 V. Troubleshooting 5.1 Service Mode .................................................................................... 5-1 (1) Service mode functions ............................................................... 5-1 (2) Service mode procedure ............................................................. 5-2 (3) F4 mode ...................................................................................... 5-4 (4) F5 mode Copier function programming ..................................... 5-16 (5) F6 mode Adjustment and programming .................................... 5-23 (6) F7 mode electronic counter ....................................................... 5-29 (7) F8 mode copier operation adjustment ...................................... 5-31 (8) F9 Telephone# input ................................................................. 5-33 5.2 Self-diagnostics/Machine Malfunctions ........................................... 5-34 (1) User error .................................................................................. 5-34 (2) Paper Jam ................................................................................. 5-40 (3) Machine error ............................................................................ 5-43 5.3 User Preset Mode ........................................................................... 5-58 VI. Unpacking/Installation 6. 1 Installation Requirements ............................................................... 6-1 6.2 Contents Check ............................................................................... 6-1 6.3 Unpacking ........................................................................................ 6-1 6.4 Installation Procedure ...................................................................... 6-2 6.5 Adjustment ....................................................................................... 6-7 6.6 White Density Adjustment .............................................................. 6-10
Caution: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacture's instructions.
For Sweden, and Denmark SPECIALSÄKRING: ENDAST AV APPARATFABRINKANTEN LEVERERAD SÄKRING FåR ANVÄNDAS. VARNING! Explosionsfara vid felaktigt batteribyte. Använd samma batterityp eller ekvivalent typ som rekommenderas av apparattillverkaren. Kassera använt batteri enligt fabrikantens instruktion. ADVARSEL! Lithiumbatteri--Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Lever det brugte batteri tilbage til leverrandoren. CAUTION! Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent recommended by the manufacturer. Dispose of used batteries according to the manufacturer's instructions.
For Holland
NL
Batterij niet weggooien, maar inleveren als KCA.
ii
For U.K.
FOR YOUR SAFETY PLEASE READ THE FOLLOWING TEXT CAREFULLY. This appliance is supplied with a moulded three pin mains plug for your safety and convenience. A 13 amp fuse is fitted in this plug. Should the fuse need to be replaced please ensure that the replacement fuse has a rating of 13 amps and that it is approved by ASTA or BSI to BS1362. Check for the ASTA mark or the BSI mark on the body of the fuse. If the plug contains a removable fuse cover you must ensure that it is refitted when the fuse is replaced. If you lose the fuse cover the plug must not be used until a replacement cover is obtained. A replacement fuse cover can be purchased from your local Panasonic Dealer. IF THE FITTED MOULDED PLUG IS UNSUITABLE FOR THE SOCKET OUTLET IN YOUR OFFICE THEN THE FUSE SHOULD BE REMOVED AND THE PLUG CUT OFF AND DISPOSED OF SAFELY. THERE IS A DANGER OF SEVERE ELECTRICAL SHOCK IF THE CUT OFF PLUG IS INSERTED INTO ANY 13 AMP SOCKET. If a new plug is to be fitted please observe the wiring code as shown below. If in any doubt please consult a qualified electrician.
WARNING: THIS APPLIANCE MUST BE EARTHED. IMPORTANT: The wires in this mains lead are coloured in accordance with the following
code: Green and Yellow Blue Brown :Earth :Neutral :Live
As the colours of the wires in the main lead of this appliance may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: The wire which is coloured GREEN-AND-YELLOW must be connected to the terminal in the plug which is marked by letter E or by the safety EARTH symbol " " or coloured GREEN or GREEN-AND-YELLOW. The wire which is coloured BLUE must be connected to the terminal in the plug which is marked with the letter N or coloured BLACK. The wire which is coloured BROWN must be connected to the terminal in the plug which is marked with the letter L or coloured RED. How to replace the fuse. Open the fuse compartment with a screwdriver and replace the fuse.
Fuse Fuse
iii
Introduction
1. 1 Specifications
1.Type 2.Copy process 3.Development process 4.Maximum original size 5.Copy speed (cpm) Ledger/A3 : Legal/B4,FLS : Letter-R/A4R : Letter/A4 : Invoice/A5 : 6.First copy time (sec) letter/A4 size without Auto mode letter/A4 size with Auto mode 7.Copy ratio Desk Top Electrostatic photographic method Two component magnetic brush Ledger(11"x17") / A3(297 x 420mm) FP-7818 FP-7824 12.5 14 15.5 18 FP-7830 FP-7835 FP-7845 FP-7850
15.5/16.0 18.50/19.00 20/20.5 17.5/17.0 21.00/20.50 23.5/23 19.5/19.0 24.00/23.50 28.5/27.5 24.0 30.00 35 45 43/41.5 50
18 24.0 30.00 35 45 50 FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 4.8 6.2 4.0 5.1 4.0 5.1 4.0 5.1 2.9 3.6 2.9 3.6
Enlargement(fixed) Reduction (fixed) Zoom
: 2.00, 1.73, 1.41, 1.22, 1.15 : 0.87, 0.82, 0.71, 0.58, 0.50 : 50%-200% (1%step)
8.Copy size 9.Paper capacity 10.Paper feed 11.Paper exit tray capacity 12.Paper weight
Ledger/A3Invoice/A5 Cassette : 550 sheets x 2 (550 sheets:FP-7818) Multi-feed bypass : 50 sheets Front loading universal paper cassette Multi-feed bypass tray 250 sheets Cassette Bypass : 1624 lbs ( 6090g/m2) : 1530 lbs (55130g/m2)
13.Special paper 14.Continuous copying
OHP,Label paper, Tracing paper (Through multi-feed bypass) 1-999 reset to 1 (1-99 reset to 1 : FP-7818)
1-1
Introduction
Section I
15.Fusing system 16.Photoreceptor 17.Exposure control 18.Warm up time
Heat and Pressure Organic Photo Conductor(OPC) 7 step digital+Photo/Auto button FP-7818 approx. 40 sec. FP-7824 approx. 50 sec. FP-7830 approx. 75 sec. FP-7835 approx. 75 sec. FP-7845 approx. 180 sec.
19.Power consumption
FP-7850 approx. 270 sec. Less than 1.45 kW/1.5 kW
20.Power source AC120V 60Hz / AC220 - 240V 50Hz 21.Dimensions (W x D x H) 23.9" x 26.0" x 22.9" / 606 x 661 x 582 mm 22.Weight (23.9" x 26.0" x 18.1" / 606 x 661 x 479 mm : FP-7818) (PU) (PG) FP-7818 138.6 lbs / 64 kg FP-7824 149.6 lbs / 70 kg FP-7830 149.6 lbs / 70 kg FP-7835 149.6 lbs / 70 kg FP-7845 161 lbs / 73.5 kg FP-7850 161.5 lbs / 73.7 kg 23.Ambient conditions 24.Optional accessories Temperature : 5086F/1030 °C Relative humidity : 3080% i-ADF ADF Sorter FA-A888 FA-A505 FA-S280 (10bin sorter: FP-7818/7824/7830) FA-S575/S660/S680 (20bin sorter: except FP-7818) System console LCC FA-DS72: FP-7818/7824/7830/7835 FA-DS82: FP-7845/7850 FA-MA301
* Specifications are subject to change without notice.
1-2
1. 2 Features
· Introducing Qualitative Reasoning Based Adaptive Controller copy density control
With Qualitative Reasoning Based Adaptive Controller used for copy density control, optimum copies are maintained for a long time in variable environmental conditions. Introduction
· User friendly operation
The touch panel enables simple operation. (FP-7845/7850)
· Enhancements in serviceability
If a problem should occur the self diagnosis system will indicate which area is responsible.
· Standard Automatic Duplexing (FP-7850)
An Automatic Duplex Unit is provided as standard, in addition to front paper loading (550 sheets) + Multiple sheet bypass (50 sheets).
· Functional expansion through optional accessories
Equipping with the system stand and LCC allows a high copy volume Maximum feed paper capacity FP-7818 2,250 sheets : four drawers + multiple sheert bypass FP-7824 2,800 sheets : five drawers + multipler sheet bypass FP-7830/7835/7845 FP-7850 5,800 sheets : five drawers + LCC + multiple sheet bypass 5,250 sheets : four drawers + LCC + multiple sheet bypass
ADF and sorter can be connected with the main system easily by using exterior connectors.
· Environmental considerations
Quieter operation, lower power consumption, a higher content of recyleable plastic and our new Qualitative Reasoning Based Adaptive Controller. (FP-7830/7835/ 7845/7850)
1-3
1. 3 System Configuration
ADF i-ADF
Main Unit 50 Sorter ADU 550 Paper drawer 550
System console 550 Cover Storage LCC 3000
Accessories FA-DS72 System FA-DS82 console LCC ( FA-MA301 )
Copier
FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 x x x 1 x x x x 2 Option x x x x x x 2 Option 2 Option 1 + ADU 1 + ADU
Standard Standard
x
x
x
Number of drawer
paper feed Auto Duplex unit (FA-MADM6)
ADF
ADF i-ADF
FA-A505 FA-A888
10bin sorter FA-S280 Sorter 20bin sorter FA-S575 20bin staple sorter FA-S660/S680
Key: System Console FA-DS72: Storage tray,Cover x 1
= OK x = N/A
( 2 drawers drive mechanism ) FA-DS82: 550 sheets paper drawer, Storage tray, Cover ( 3 drawers drive mechanism )
1-4
[ Comparison of specifications ]
FP-7818 FP-7824 FP-7830 FP-7835 FP-7845 FP-7850 Warm up time ( sec.) First copy time ( sec.) Paper feed cassette System stand Copy speed Control panel design Transfer corona cleaner Drum separation finger Fuser lamp Process speed ( mm/sec. ) Developer suction Fresh toner recycling Toner bottle life Waste toner bottle capacity PM cycle Department counter Cover, Interleaving, Presentation Job memory 40 4.8 1 DS72 18 LED No No 1 170 No No 10K 10K 80K 50 No * 2 50 4.0 2 DS72 22 LED No No 1 210 No No 10K 10K 80K 50 No * 2 70 4.0 2 DS72 28 70 4.0 2 DS72 35 180 2.9 1+ADU DS82 42 210 2.9 1+ADU DS82 50
LCD display LCD display No No 1 210 No Yes 20K 120K 120K 100 No * 2 No No 1 210 No Yes 20K 120K 120K 100 No * 2
LCD touch panel LCD touch panel
Yes Yes 2 340 Yes Yes 20K 120K 120K 300 Yes 5
Yes Yes 2 340 Yes Yes 20K 120K 120K 300 Yes 5
* Except OHP Interleaving
This Service Manual is based on the FP-7850. To identify areas where the other models differ, please refer to this chart and the Field Service Manual for each model.
1-5
Introduction
1. 4 Operation
· FP-7818/7824/7830/7835
Energy Saverkey Reset Key Interrupt Key Clear/Stop Key
LEDGER LEGAL LETTER INVOICE
1 2 3 4 5 6 7 8 9 0
Recall Key Original Size Keys Special Effects Panel Communications Monitor
To recall the number of copies selected during a copy run.
Copy Size Keys
Quantity Keys Print Key
· FP-7845/7850
Energy Saver User Preset Key Touch Panel Display Interrupt Key Reset Key Manual Key
Press to reset all features to initial power-on state.
1 2 3 4 5 6 7 8 9 0
Multi Size Key
Original Size Keys
Quantity Keys
Ready Indicator
Ready: Green LED Not ready: Red LED Copy Reservation: Flashing
Clear/Stop Key
Press to stop copy run or clear copy count in display.
Job Memory Key
Copy Size Keys
Print Key
1-6
(1) Special Effects Panel (FP-7818/7824/7830/7835)
Introduction
1 2 3 4
123
OHP OHP
13
OHP OHP
5 6 2 1 7 8 2
M
12
1 2
9
M1
M2
11
10
No.
1
Keys Multi-Size Feeding (Except FP-7818/7824) · Using i-ADF Original Count (Except FP-7818/7824) · Using i-ADF and ADU 2 in 1 mode Access User Preset OHP interleaving mode Zoom Margin Shift Mode
No.
8 9 10 11
Keys Edge Mode Book Mode Memory In/Job programs Duplexing mode selection (Except FP-7818/7824) · Using ADU
2
3 4 5 6 7
12
2:1 Copy (Except FP-7818/7824) · Using i-ADF
13
2-Page copy/2 in 1 mode selection (2 in 1 : Except FP-7818/7824)
1-7
(2) Communications Monitor (FP-7818/7824/7830/7835)
1 2 3 1 4 5 6
FP-7818/7824
% mm
7
FP-7830/7835
STAPLE SORT STACK
13
LEDGER LEGAL LETTER LETTER INVOICE
14 15 16
STAPLE SORT
FP-7718
STACK
12
18
11 10
17
9
8
No.
1
Indicator Adding Paper Toner Staple (Except FP-7818) Replacing Waste Toner Bottle Reduction Enlargement Service Call · Flashes for routine maintenance. · Lights steadily for duplex maintenance Paper Misfeed Copy Count Display Indicates number of copies, zoom ratio and error code. Keys Manual Key PHOTO/AUTO Exposure Control (DARK)
No.
7
Indicator Message Display (FP-7830/7835) Indicates procedures, functions maintenance, etc., Exposure Indicator Paper Size Indicator Paper Drawer/Tray Indicator () Paper misfeed location (·) Mode Select Indicator Staple Sort (Except FP-7818) Sort Group
8 9 10 11 12
2 3 4
5 6
No.
13 14 15
No.
16 17 18
Keys Exposure Control (LIGHT) Paper Drawer/Tray Mode Select Key
1-8
1. 5 Component Location ( Outer view )
ADF Control Panel i-ADF
Bypass Sorter
FP-7818
Sorter System console FP-7824/7830/7835 LCC (Except FP-7824)
LCD touch panel i-ADF Control panel
Right cover Front panel Sorter
Bypass Paper feed cover
System console
FP-7845/7850
LCC
1-9
Introduction
(1) Inner view
1 2 3 4 5 6 7 38 8 9 10 11 12
37 36 35 34 33 13 14 15 16 17 18 19 31 30 20
32
21
29
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
28 27
26 25 24 23 22
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Paper feed roller DFP roller Pick-up roller ADU Paper feed roller Corona cleaner Transfer/Separation corona Drum Transfer belt Pressure roller Fuser lamps Fuser separation finger (lower) Reverse roller Fuser separation finger (upper) Paper exit roller Paper exit sensor Heat roller Cleaning Web roller Full-speed unit home postion sensor Drum separation finger
Half-speed unit Full-speed unit Lens Position sensor Thermistor AE Sensor Main motor Lens unit Charge corona No.6 mirror Slit glass No.4 mirror No.5 mirror LED array Magnetic roller Registration roller Bypass pick-up roller Bypass paper feed roller Bypass DFP roller Middle roller
1-10
(2) Fan/Motor Location
Introduction
Optics fan Optics fan
Mirror stepping motor Optics drive motor Lens stepping motor Developer cooling fan Toner bottle motor Dust collecting fan ADU drive motor (FP-7850)
Exhaust fan Optics fan Main motor Suction/Ozone fan Lifting motor (lower stage)
ADU paper length guide motor (FP-7850) ADU paper width guide motor (FP-7850)
1-11
(3)Sensor Location
Mirror home position AE (Automatic original density sensor) Original size Exposure lamp home position Lens home position Paper exit Front cover open/close ADU paper pass 1 (FP-7850) ADU paper length (FP-7850) ADU paper pass 2 (FP-7850) ADU paper detection (FP-7850) ADU paper width (FP-7850)
Platen cover angle Platen cover open/close Paper feed cover open/close Toner bottle home position Toner level Bypass paper size Bypass paper detection Total counter Waste toner bottle Middle roller paper pass (upper/lower stage) Bottom plate upper limit sensor (lower stage) Registration roller paper pass Paper level (lower stage) Paper detection (lower stage)
Copy density Toner density ADU detection (FP-7850)
1-12
(4) Solenoid/Clutch/Discharge lamp Location
Introduction
1-13
Separation solenoid Paper exit solenoid (FP-7850) Door switch
Discharge lamp Registration roller clutch Middle roller clutch Paper feed clutch Bypass pick-up solenoid
Power switch
Paper feed clutch (lower stage) ADU clutch (FP-7850) Pick-up solenoid (lower stage) Recycle solenoid
(5) PCB Location
Control panel 3 LVPS (Low voltage power supply) Control panel CPU Control panel 4 HVPS (High voltage power supply) AC driver Main CPU Paper feed driver Automatic duplex unit driver (FP-7850) LED array
1. 6 Copy Process
DC
Charger Discharge lamp
Blacking prevention
Trimming Exposure Cleaning Developer
Reduction Discharge
Original Toner
Separation
Transfer
Exit
Fusing ADU
Paper feed
Primary Charge:
Charge corona Drum
Image Exposure:
Illumination
Developing:
Latent charge image() Toner (+)
Drum surface approximately-800V DC Transfer/Separation
Latent image Toner
Latent charge image
Magnetic roller
Fusing:
Heat roller Fuser lamp Paper
Cleaning:
Cleaning blade
Drum
Paper Separation corona Transfer corona
Pressure roller
Discharge lamp:
Discharge lamp
1-14
1. 7 Precautions on Set Up
Copy machine performance and the copy quality is subject to and dependant on environmental conditions. To maintain good performance, quality, and safe operation, observe the following precautions: Introduction
1)
For safe operation and to avoid trouble do not install the system under the following conditions: · High temperature, high humidity, low temperature or low humidity · The temperature or humidity varies suddenly · Being exposed to direct sunlight · Dusty space · Badly ventilated location · Exposed to chemical gases (such as ammonia gas) · Exposed to strong vibration · Directly exposed to direct wind (ex. outlet of air conditioner)
2) 3)
The weight of machine is 220lb(100 kg) or more with options. It must be placed on a firm platform which is level. The maximum power consumption is 1.45 kW. Use an independent power supply of 120 V and 15 A (220-240V and 7A)or higher. (Do not use a extension cord.) Make sure the machine is properly grounded. (Do not ground to gas or water pipe.) · A ground terminal is provided on the back of the copier main body.
4)
5)
Install the machine with enough space around it.
4"/100 mm
14"/350mm
28"/700mm
Exit tray
Copier
Multi sheet bypass
1-15
1. 8 Precautions with Consumables
(1) Photoreceptor drum · Do not touch the surface (with the hand or anything else). · Stand the drum with the drum gear up for storage. · Be careful not to smear with saliva, water, oil and so on. · Do not place a where the temperature is high. · Do not place it in strong light (such as direct sunshine or at window). · Do not expose it to chemical gas or vapor. · Do not store the developer unit with the photo receptor drum installed without covering it with clean paper. (2) Toner Developer 1) Do not mix different types of toner and developer. · The machines are designed to use exclusive toner and developer for specific models. Do not mix with toner and developer for other models. 2) Do not mix foreign materials. Be careful not to include foreign materials in the toner and developer. If you spilled toner or developer on a table or floor when adding toner or developer in the developer unit, discard what was dropped. Such supplies may damage the drum as well as cause other trouble with the image. 3) Do not place into other containers. Toner and developer must not be placed into other containers, because some containers may change the characteristics of the supply. Vinyl chloride potentially changes the characteristics of supplies because of migrating plasticizers. 4) Precautions on storage and transport · Toner and developer additives are sensitive to temperature (high temperature in particular) and humidity (high humidity in particular). Pay attention to the following items for storage and transport. · Store them in a dark and cool location (lower than 95 F/35 C) and out of direct sunshine. · Be careful not to expose them to rain or direct sunshine during transportation. When delivered by truck the temperature inside must be not higher than 104 F/40 C. (Under the sun in summer, the inside temperature can typically be 140 F/60 deg.C or higher in a closed vehicle compartment.)
1-16
5) Safety and hygiene Toner has the property of easily being wind blown. Toner on skin does not cause any damage to health but, inhaling it is undesirable even if a powder is simply dust. Therefore, be careful not to inhale toner . · Handle the toner gently when changing cartridges, and developer when pouring in the developer unit. If you have breathed in a lot of toner by mistake, rinse out your mouth with water completely. Any toner on the skin should be washed off with soapy water. · Toner stuck on clothing must be removed in a dry condition (by a vacuum cleaner, brush, or beating,) and then washed with soapy water. Wiping off with benzine, alcohol, or thinner is not recommended because it may partially melt the components of toner even more, resulting in a harder stain and spot. · Toner spilled must be cleaned with a vacuum cleaner, and then wiped with a cloth dampened with a neutral detergent and wrung out. · If exposed to flames toner and developer will burn. Keep these supplies away from open flames. · Any wasted consumables (photo receptor, developer and toner) should be recycled. · Wear rubber gloves, eye protection and so on before handling any solvents such as IPA.
1-17
Introduction
· There are normally no special problems with storage and transport in a cold climate but, store in a low humidity condition. Do not put supplies near heaters.
Section II Control Functions
2. 1 Image Control Qualitative Reasoning Based Adaptive Controller
· Even if the toner density is at it's standard level, the copy image may vary with time depending on the characteristics of drum and the environmental variations. To prevent this change, the copy density sensor which is installed under the developer unit controls the image to stablize the copy image. · Controlling the image During initialization after turning on the power, the copy density sensor reads the white density, medium density (line pattern density patch) and black density developed on the drum surface.These three values are compared with the ideal gamma curve stored in the copiers memory. The copier detects the amount offset from the standard gamma curve (such as "a little background" or "light image") and calculates the variables for copy density control in accordance with Qualitative Reasoning Based Adaptive Controller. In this way it finds the optimum compensation values to tighten the gamma curve for maintaining peak copy quality. By means of this process, copy quality is stabilized by the various compensations enabled by Qualitative Reasoning Based Adaptive Controller adjustment in image production. · The control of the gamma curve stabilizes copy quality by monitoring three points of copy quality (white density, medium density and black density) and has a direct effect on background, solid area density and good reproduction of fine lines regardless of environmental changes and variation with time and copy volume. Control Functions
2-1
· Qualitative Reasoning Based Adaptive Controller Qualitative Reasoning Based Adaptive Controller is adaptive control on the basis of quantative reasoning theory. While successively reasoning and learning the change of process characteristics regardless of environmental changes and the variations with time and the number of copies on the copier, the system reads the patch marks and determines the best values of exposure and surface potential to establish the best gamma curve for optimum copy quality. · Qualitative Reasoning Based Adaptive Controller is applied at the following intervals. a) During initialization after turning on the power. b) After every 1,000 sheets following execution of Qualitative Reasoning Based Adaptive Controller (But, every 200 sheets following the execution of F8-09 for the next 500 sheets) c) After turning on the power (up to 200 copies) d) After replacing the toner bottle (up to 200 copies) · Copy density detecting sensor Two sensors for detection of copy density are used, one for white density, and line pattern density and one for detection of black density. (Temperature and humidity sensors are not used.) · To correct for toner build up on the sensor, clean the sensor at the same time as the replacement of the drum. The system provides a measured amount of light and detects the reflected light. The resultant value is used for sensor compensation. This becomes the reference value. · As the reference value of the white density changes, various components are adjusted according to characteristics of the gamma curve. Reference F mode F5-25: Qualitative Reasoning Based Adaptive Controller Operation ON/OFF F6-80: Automatic compensation value (read only) F6-81: Automatic compensation value (read only) F6-82: Automatic compensation value (read only) F6-28: White density reference value (set by Qualitative Reasoning Based Adaptive Controller) F6-29: Black density reference value (set by Qualitative Reasoning Based Adaptive Controller)
2-2
2. 2 Toner Density Control
To keep toner density(toner carrier ratio) in the developer unit constant, the TDC sensor (toner density sensor) which is installed under the developer unit detects the amount of carrier in the developer unit to control the toner density.
(magnetic power) in the developer (mixture of toner and carrier) is detected by the TDC sensor and is converted to a voltage to control the toner density. Control Functions The change in magnetic flux density in accordance with the amount of carrier
Amount of carrier passing TDC sensor Less Much Toner density condition Sensor output voltage High Low Lower than normal Higher than normal
The following controls are necessary for normal control of toner density 1) Automatic adjustment of TDC sensor gain (during execution of F8-C09) (to attain the standard reference level). 2) Maintain the standard level by control of toner density during use.
1) Automatic adjustment of TDC sensor gain Automatically adjust the reference through the TDC sensor by executing service mode F8-09. The operation flow is as shown below.
F8-09 start CPU will check toner density sensor output. (2.5 V) Yes No CPU will adjust sensor gain control signal Memory number will be changed to new number in memory. (F6-21 or F6-26)
Toner density sensor output voltage will be adjusted to 2.5 V
2-3
2) Maintain standard toner density While checking the output voltage of the TDC sensor for every copy, control the timing of toner supply to the developer unit so that the output voltage is 2.5V at all times to keep the toner density constant.
Check TDC sensor output voltage at copying (or mixing). Is the measured output voltage over 2.5V? NO YES Supply toner: supply from reserve tank for 6 seconds (amount of toner supply: approx. 1.4 g) Rotate bottle for 7 seconds: supply toner to reserve tank. (Toner is not supplied to developer unit.) Do not supply toner. Note) During bottle rotating, toner is not supplied.
(Reference 1) Toner supply route
Bottle Reserve tank (hopper) Developer unit
(Reference 2) Forced toner supply
Supply toner: supply for 4 seconds from reserve tank. (amount of toner supply: approx. 1.1 g) Perform twice. Rotate bottle for 7 seconds: supply toner to reserve tank. (Toner is not supplied to developer unit.)
Note: Bottle rotation means toner is being added to the reserve tank, not the developer unit. This is not a final confirmation for proper TDC adjustment.
2-4
2. 3 Trouble Avoidance Mechanism
When some malfunction happens, this mechanism allows regular copy operation without error conditions (service man call) (providing the malfunction does not affect the basic copying operation and the appropriate function is not selected).
Appropriate function selected The selected function is unavailable, repair is necessary, select others. "(EX-XX)" EX-XX (Error code) Appropriate function not selected Normal indication of copying
User mode
Service mode
XXXXXX (Electronic counter value at malfunction)
Note: Only 30 records can be stored. Earliest records are replaced by new ones as space is required.
2-5
Control Functions
Item Copier paper feed ( upper ) Copier Paper feed ( lower ) System stand paper feed ( upper ) System stand paper feed ( middle ) System stand paper feed ( lower ) System stand paper feed timing LCC Lift up LCC Lift down Duplex unit ( length ) Duplex unit ( width ) duplex unit ( sensor ) Stapler Sorter ADF ( motor ) ADF ( sensor ) Error code E2-01 E2-02 E2-03 E2-04 E2-05 E2-10 E2-06 E2-07 E6-03 E6-04 E6-05 E7-06 E7-07 E7-10 E7-11
Copier
Accessories
2-6
2. 4 Toner Recycling System
To maximize the number of copies which can be produced for each bottle, toner cleaned off of the drum needs to be returned to the developer for re-use. Under normal circumstances, the copy process can damage some toner. In addition, other undesireable materials may be cleared from the drum surface and mixed with reControl Functions useable toner (such as paper dust, etc.). Toner Recycling System allows us to maximize toner yield, while avoiding the potential side effects of recycling used toner.
There are two methods of handling the mixture of materials found in the cleaning unit following the drum cleaning. This handling is normally in the "Recycle" mode, but on a regular basis is switched to the "Refresh" mode. During the "Refresh" mode, the undesireable particles are removed from the developer unit, and forwarded to the waste toner bottle to be discarded.
Every programmed copies (500/1000/1500/2000 as set by F5-65), Toner Recycling System directs the recycle solenoid to switch from Recycle to Refresh Mode for the next 100 copies. During the refresh cycle, the cleaning unit is emptied into the waste toner bottle, there by removing all undesireable particles from the system. This process is completed unnoticed by the end user during regular operation. Recycle Mode
Developer unit Drum Cleaning unit
Refresh Mode
Developer unit Drum Cleaning unit Waste toner bottle
Note: Toner Recycling System also monitors TDC. If the ratio becomes too high, the system will initiate the Refresh Mode automatically.
2-7
2. 5 Re-try Control for Paper Misfeed
· Copy paper should pass the paper feed sensor within a specific time after the paper feed clutch turns on. To reduce paper misfeeds due to a slipping paper feed roller, the paper feed clutch turns on again (re-try operation). · When the paper does not reach the paper feed sensor within a specific time after two re-try operations, "jam" is indicated. The re-try control for misfeeds is executed for each paper feed unit.
Paper feed motor
ON OFF
Motor off
925ms. 500ms.
ON Paper feed clutch OFF
2038ms.
Re-try
H Paper feed sensor L
2-8
Section III Sub Assemblies
3.1 Main Drive
The driving mechanism of this machine is as follows.
Main motor
Pulley 1 Pulley 2 Transport roller
Magnetic roller Drum Registration roller
Bypass unit
Middle roller
Paper feed unit
Middle gear
Middle roller Paper feed unit (Lower stage)
Name of motor Main motor
Driving method DC24V driving
Driving unit · Rotation of photo receptor drum · Developer unit, paper feed unit, paper transport, fuser unit and paper exit unit
3-1
Sub Assemblies
Fuser unit
(1) Detecting sheet bypass paper size
· The paper size for the sheet bypass is detected by a matrix of sheet bypass paper size sensors which are installed on the sheet bypass tray. · When setting the paper in the sheet bypass tray and adjusting the paper guide, the matrix is as follows.
S1/S2 Ledger/A3 Legal/B4 Letter/A4 Letter-R/A4R Invoice/A5 S4 Paper size detecting sensor S1 ON ON ON OFF OFF S2 OFF ON OFF ON OFF S4 ON ON OFF OFF OFF
3-2
(2) Developing
· The developer mixing unit contains developer which is a mixture of fine powder (non-magnetic toner) and fine ferrite carrier. · The developer is mixed by the transport screw and the mixing mill. The toner becomes charged ( + ) and the carrier becomes charged ( ). The developer is magnetically stuck on the aluminum sleeve of the magnet roller, and the magnetic brush is formed. The developer is transfered counterclockwise in the rotating direction of the sleeve. The height of magnetic brush is controlled by the gap between the doctor blade and the sleeve surface. · The drum with an electrostatic latent image (negative charge) is rotating clockwise and makes contact with the magnetic brush. · The sleeve is charged opposite of the drum and an electric field is formed. The positive toner is stuck on the electrostatic latent image on the drum. · The sleeve has applied ( ) bias voltage, which prevents the drum from covering with toner. The distance between the drum and the sleeve is controlled with the spacer rings.
Amount of developer Initial toner density DSD BSD Developing bias voltage Approx. 650 g 4.0 % 0.8 mm 0.61 mm 250 V reference N2 S1 S2 N1 N2 S3
Reference: · The twin field magnet roller presents enhanced developing performance by a wider developing area which results from two pole peaks (S1 and S2 pole) facing the drum surface. · N2 through S3:Attract the developer to the sleeve from the mixing mill. · S3 pole: Raise the head of developer and control the head height with the doctor blade. · N2 through S1: Transfer the developer to the developing position. · N1 through N2: Separate the developer from the sleeve.
3-3
Sub Assemblies
(3) Supplying toner
The Toner Hopper Unit supplies toner to the Developer Mixing Unit via the Reserve Tank, so toner addition is done in two stages, by turning the Toner Hopper Motor in either direction: Forward Direction: The bottle turns (via a spring clutch) to supply toner from the Toner Bottle to the Reserve Tank. This direction is controlled by the Toner Volume Sensor. Reverse Direction: The Toner Supply Roller turns (via a spring clutch) to supply toner from the Reserve Tank to the Developer Mixing Unit. This direction is controlled by the TDC Sensor.
TDC sensor output Toner empty Hopper sensor motor High (Lower toner density) High Low (Higher toner density) Low Detect Reverse rotation
Toner bottle --
Toner supply Add toner roller Rotate -- -- -- Supply toner to developer unit Supply toner to sub-hopper -- --
Non detect Forward rotation Rotate Detect Not detect Stop Stop -- --
· A toner supply by the toner supply roller (approx. 16 seconds) can supply 1.4 g of toner of to the hopper. · Separating the developer mixing unit from the toner supply unit of toner hopper, the toner supply shutter is closed to prevent toner drop.
3-4
(4) Toner level detection
· When the toner level sensor in the toner hopper detects no toner remaining, and does not detect toner after continuously turning the toner bottle "Add toner" is displayed. The copier is disabled. The machine can be used after the user's key input. After lighting the no toner indication, the machine stops after 300 copies. The "Add toner" indication is cleared by replacing the toner bottle. Detecting the toner bottle position Sub Assemblies · Insert the toner bottle in the hopper and turn to the specified position. Accordingly, the toner bottle shutter opens and is able to add toner to the hopper. · The bottle home position sensor which is mounted in the toner hopper detects the position of the toner bottle and the toner bottle stops turning at the specified position.
3-5
(5) Temperature control
The heat roller is provided with two halogen lamps (main heater lamp and sub heater lamp). The main heater lamp turns ON during warming up and copying operation. To control the maximum power consumption, the sub heater lamp turns ON during warming up and after release of pre-heat mode only in order to reduce the warming up time of fuser unit. The temperature control in the copying operation and the standby is done by the main heater lamp. · Sequence a) When turning ON the power, the main heater lamp and the sub heater lamp turns ON, which heats the heat roller. b) At a specified temperature, the main motor turns on and the heat roller and the pressure roller rotate. After all copy quality standards are set, the main motor turns off. When the heat roller temperature reaches the specified value, the machine is ready. c) Afterwards, the thermister detects the temperature of heat roller. The heat roller keeps the temperature to the specified value by turning on/off the main heater lamp. (Note) · When the temperature of heat roller surface does not reach the specified value in the specified time from power ON, the error E4-01 is indicated. · If when the power is turn ON in an absolutely frozen condition of fuser roller (a very cold morning) or copies are continuously made, the operation of main heater lamp is inadequate. In this case, the number of copies per min. will be reduced (no change for process rate)to increase fusing time. When the temperature of the heat roller surface rises enough, the machine speed will return to the regular number of copies per min.
Switch ON (°C) 190 175 Heat roller surface temperature Warm-up complete Print key ON Energy Energy Copy complete Saver ON Saver OFF
0
210 sec.
Time
Main motor Main lamp Sub lamp
3-6
(6) Automatic detection of original paper size
· Opening the platen cover by approx. 30 degrees to insert the original, the platen cover angle sensor turns on and four original size detection sensors operate simultaneously. · The original size detection sensors consists of light emission unit and light reception unit. The light from the light emission unit is thrown on the original and the reflected light is received by the light reception unit to check the existence of the original. · The original size is read again by turning on the platen open/close detecting sensor when closing the platen cover. · The automatic original size detecting operation is released when pressing "original size selector" key in the control panel, setting the original in ADF or selecting "0" for F5-52. Detect ( Original size detection matrix ) No detect Sub Assemblies
Original size detect sensor(1) AOS1 Ledger/A3 Legal/B4 Letter/A4 Letter-R/A4R Invoice/A5 No original Original size Original size Original size Detect sensor (2) detect semsor (3) detect semsor (4) AOS1 AOS2 AOS3 AOS4
AOS3 AOS2
AOS4
(7) Adjusting quantity of light of AE sensor
· In pre-scan, the output of the AE sensor must be at a proper level. Therefore, when operating image density control (QuantamTM Technology), the exposure lamp voltage is adjusted to be approx. 2.7V of AE sensor output when reading the standard density mark, and the system memorizes the compensation value at that time. · In pre-scan automatic exposure mode, the original reflects the light of the exposure lamp voltage adding the above compensation value, and the original density is read by the AE sensor. The result corrects the exposure before copying. Reference: Service mode for adjustment (for details refer to the "Field Service Manual") F6-01: Compensation of vertical copy ratio (compensating scanning speed of optics unit) F6-02: Compensation of full size focus F6-03: Compensation of horizontal copy ratio (compensating lens position) F6-05: Compensation of paper registration position (Compensating timing roller clutch turning on timing) F6-11: Compensation of quantity of exposure light for full size F6-12: Compensation of quantity of exposure light for photo mode F6-16: Compensation of quantity of light for AE sensor
3-7
Section IV Preventive Maintenance
The periodic maintenance service is performed by machine cleaning and parts replacements. It is essential to perform these service activities properly for customer satisfacation. The purpose of this service is to maintain the machine performance and the copy quality.
4. 1 Precautions for Periodic Maintenance Service
· You should get the customer's agreement for when and where the maintenance service is performed. · You should completely explain the philosophy maintenance service is not to repair problems, but to avoid them. · You should prepare the necessary replacement parts and tools for cleaning beforehand. · After finishing the maintenance service, you should discard the waste parts and papers, and clean the surrounding area. · Let the customer know when you are finished. · Before removing the equipment, pull out the plug. · Before using solvents such as IPA (isopropyl alcohol), put on rubber gloves and eye protection. · Perform the periodic maintenance service in accordance with the chart of periodic maintenance areas. Preventive Maintenance
(1)
Timing
(2)
Cleaning of roller
· Rollers should be cleaned with water and cloth. · Use IPA (isopropyl alcohol) if they are very dirty.
(3)
Precautions for disassembly and adjustment
· Before disassembling the machine, disconnect the power plug. · After taking apart, do not operate the machine. When operating the machine with the cover removed, be careful so that clothes are not caught by moving components. · When electricity is applied, the connectors on any P.C.B. must not be connected or disconnected. · Using a vacuum cleaner for the cleaning of the TDC sensor could cause electrostatic damage, therefore, use blower brush and cotton swab for the cleaning of these parts. And, before cleaning any units, remove the sensors beforehand. · For the drum, comply with the precautions shown in 1.8 "Precautions with consumables". · Make sure to use the correct screw sizes. · Use toothed lock washer for the installation of ground wires to secure electrical continuity. · Reassemble parts in the reverse sequence of the disassembling unless otherwise noted. · Replace blown fuses with the specified rated ones. · Do not let the lithium battery on P.C.B short-circuit.
4-1
4.2 Maintenance chart
1) Replacement Maintenance cycle FP-7818/7824 : per 80,000 copies FP-7830/7835/7845/7850: per 240,000 copies
Item Paper feed unit Service Paper feed roller DFP Roller Pick-up roller Cleaning sheet (Except FP-7818/7824) Registration roller Registration roller bearing Middle roller Torque limiter (Bypass) Torque limiter (Copier) Developer unit Cleaning blade Wire Developer (FP-7818/7824) Part number FFPMA05411 FFPMA05411 FFPMA0542 FFPHK0951 FFPMA0539 FFPMQ0559 FFPMA05451 FFPXQ24H00 FFPXQ04H00 FFPHK0942 FFPXL05H00 FQ-ZK10 Q'ty per Maintenance cycle (x 1000) unit 2 2 2 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X X 80/120 160/240 240/360 320/480 400/600 X X X X Replace at 1,080,000 copies Replace at 1,080,000 copies Replace at 1,200,000 copies Replace at 1,200,000 copies Replace at 1,200,000 copies X X X X X X X X X X X X Replace at 10,000 copies X X X X
Developer FQ-ZK20 (FP-7830/7835/7845/7850) Drum (FP-7818/7824) FQ-HK10 Drum FQ-HK20 (FP-7830/7835/7845/7850) Side seal (Front) FFPXG51H00 Side seal (Rear) Spacer ring (Front) (FP-7818/7824) Spacer ring (Front) (FP-7830/7835/7845/7850) Spacer ring (Rear) (FP-7818/7824) Spacer ring (Rear) (FP-7830/7835/7845/7850) Waste toner bottle (FP-7818/7824) Waste toner bottle (FP-7830/7835/7845/7850) Toner dispersion cover FFPXG50H00 FFPHQ0057 FFPHQ0061 FFPHQ0058 FFPHQ0062 FFPQA0164 FFPQA0165 FFPXG08H00
Magnetic roller stopper (Front) FFPXG06H00 (Except FP-7818/7824) Magnetic roller stopper (Rear) FFPXG07H00 (Except FP-7818/7824) Drum separation finger FFPLK0332 Corona FFPXG60H00
4-2
Item Fuser unit
Service Separation finger (Upper) Separation finger (Lower) Thermister Fuser lamp (850W)
Part number FFPLK0331 FFPLK0231 FFPBL0015 H12V085WN2A
Q'ty per Maintenance cycle (x 1000) unit 5 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 X X X X X X X X X X X X X X X X X X X X X X X Replace at 1,200,000 copies X X X X X X Replace at 1,200,000 copies X X X X X X X 80/120 160/240 240/360 320/480 400/600 X
Cleaning web FFPKM0316 (FP-7818/7824) Cleaning web FFPKM01343 (FP-7830/7835/7845/7850) Cleaning web pressure roller FFPMA0470 (Except FP-7818/7824) Heat roller (FP-7850) FFPMA0590 Heat roller (FP-7845) Heat roller (FP-7830/7835) Heat roller (FP-7818/7824) Heat roller bearing Heat roller gear Fuser entry guide (lower) Pressure roller (FP-7818/7824) Pressure roller (FP-7830/7835) Pressure roller (FP-7845/7850) Pressure roller bearing Heat-insulating bushing Optics unit Exposure lamp Dust protection filter A Dust protection filter B Filter A Filter B Main body Suction/Ozone filter Ozone filter 1 FFPMA0566 FFPMA0577 FFPMA0574 FFPMQ0572 FFPMF1057 FFPKF1308 FFPMA03582 FFPMA04181 FFPMA0565 FFPMQ0573 FFPJF0034 E08V025WN2A FFPJD00382 FFPJD00421 FFPGB0022 FFPGB0023 FFPHJ0039 FFPHJ0038
Ozone filter 5 FFPHJ0042 (FP-7830/7835/7845/7850) Ozone filter 7 FFPHJ00461 (FP-7818/7824) Dust protection filter FFPHJ0049 Discharge lamp Transfer/Separation corona Wire 1 Wire 2 Wire cleaner ADU Paper feed roller DFP roller F/R Mylar Storage roller Paper feed pad PQ24V10WMG2 FFPVL01H01 FFPXL04H00 FFPXL05H00 FFPXL01H00 FFPMA0558 FFPMA0559 FFPXD07J00 FFPMA0557 FFPKP00821
4-3
Preventive Maintenance
4.3 Cleaning Method
· Cleaning method for each PM service visit is shown below.
14
17
20
25
19
18
22
9
8
17 24
23 10
1
2
3 7
4 30 5 15 16 13 11 21 12 6
4-4
Cleaning position 1 Sheet bypass paper transfer roller 2 Sheet bypass paper feed roller 3 Timing roller 4 Middle roller 5 Paper feed roller 6 Paper transfer roller 7 Cleaning sheet 8 Corona wire 9 Corona grid / Corona case
Tool/solvent Cloth with water / IPA
Work/precaution - Use IPA, if toner is stuck on the rollers. (As little as possible.) - Do not use cleaning cotton.
11 Transport belt 12 Transfer corona wire / Corona case/ Transfer guide plate 13 Fuser guide plate 14 Fuser thermister 15 Fuser separation finger (upper/lower)
Cloth with water
Cloth Cloth Cloth
- Remove toner dust on separation finger. - Don't damage separation finger edge. - Use IPA, if the roller is very dirty. (to be continued)
16 Fuser heat roller / pressure roller
Cloth
4-5
Preventive Maintenance
Paper feed unit Developer unit Fuser unit
Brush / IPA Cloth with water
- Remove paper dust by brush deleted. - If not replaced at PM cycle, high voltage leak may occur. - Pay attention when replacing corona wire (No sagging or kinking) - Do not use cleaning cotton. - Lift the developer unit (mag-roll side) up 45, and rotate mag-roller 4~5 times counterclockwise. Remove the toner dust on lower developer frame by brush or vacuum cleaner. - Clean the lower developer frame by cloth with water. - Clean by cloth with water.
10 Lower developer frame Brush / Dust cover Vacuum cleaner / Cloth with water
Cleaning position 17 Mirror (No.1 ~ 6) Optics unit
4-6
18 Lens
Tool/solvent Work/precaution Blower - Clean with soft touch, otherwise, brush / the mirror surface may get Glass damaged cleaning - Clean with soft paper and IPA as paper with required. IPA Blower brush Cloth with water Cloth/Blower brush IPA IPA Cloth Vacuum cleaner Cloth with water / Neutral detergent Cloth with water / IPA - Clean the dust on the sensor
19 Original size detecting sensor 20 Reflector 21 Copy density sensor 22 Discharge lamp filter 23 LED array 24 Slit glass 25 Platen glass 26 Platen mat 27 Ozone filter 28 Dust collection filter 29 Outer cover
Main body Duplex unit
30 Paper feed roller
- Same as paper feed unit
4. 4 Disassembly and Re-assembly
PM parts replacement procedure
· The replacement procedure of PM parts is as shown below. The replacement cycle of PM parts is shown for the FP-7750/7742. (For other models, refer to the correct Service Manual.)
Multi-feed bypass 4-6 Main body 4-30
Fuser Unit 4-17
Optics Unit 4-22
ADU 4-27 Paper feed Unit 4-9
Drum Unit
Developer Unit 4-12
4-7
Preventive Maintenance
(1)
Multi-feed bypass Item Part name 1 Pick up roller 2 Paper feed roller 3 DFP roller 4 Torque limiter 5 Registration roller 6 Registration roller bearing 7 Cleaning sheet Cycle 120K 120K 120K 1200K 1080K 1080K
5, 6 4 3 2 1
600K
7
Caution
Magnet clutch Hook Hook "D" cut "D" cut
Welded point (Front view) (Side view) Welded point
When removing the magnet clutch, push the hook 1 , out of the slot and slide the magnet clutch in the arrow direction 2 , in order to avoid welded point damage.
4-8
1) Replacement of the pick-up roller/paper feed roller
1
2
(1)Remove the screws and covers. (x 2) (2)Disconnect the harness. (3)Remove the bypass tray. Note: Remove right cover (2 screws).
1
3
1
2
(1)Remove the touch ring.
7
(2)Remove the paper stopper. (3)Remove the sensor lever. (4)Remove the touch ring. (5)Remove the pick-up roller
6
1 3 2
4
(6)Remove the touch ring. Preventive Maintenance
4-9
(7)remove the paper feed roller.
SV103
2) Replacement of the DFP roller and torque limiter
3
*Conduct the procedure 1. *Open the copier paper feed cover. (1)Press the DFP roller lower side then remove touch ring. (2)Remove the DFP roller. (3)Remove the torque limiter. (4)Check the rotation of the torque limiter.
3 1 2
3)
Replacement of the registration roller and cleaning sheet 1) Remove the right cover and rear cover. 2) Open the front cover.
3 4 3 5 5
4
a) Open the waste toner bottle cover and remove the bottle. b) Turn the toner hopper 180°.
2a
3) Pull and turn the developer release knob. 4) Remove the drum unit. 5) Remove the connector and developer unit.
5
1a
2
1b
2
1) Open the copier paper feed cover and disconnect the cover link. a) Remove the knob (One screw), timing roller. b) Disconnect the harness. 2) Remove the bypass unit (Two screws).
1
6
1
1) Remove the top cover (Two screws). 2) Remove the tension spring (X 2). 3) Remove the upper registration roller. Remove the paper guide plate (Two screws).
2 4 5 7
4) Remove the E rings (both sides).
3 2 4
5) Remove the drive gear, clutch, and E ring. 6) Remove the bushing support plate and bushing (1 screw). 7) Remove the Lower registration roller.
7
2
1) Remove the cleaning sheet under the lower timing roller. 2) Remove the cleaning sheet on the top cover. 3) Clean the timing roller with IPA.
1
4) Re-install new cleaning sheets (x2).
4-10
(2) Paper feed unit Item Part name 1 Paper feed roller 2 Pick-up roller 3 DFP roller 4 Torque limiter 5 Middle roller Cycle 120K 120K 120K 1200K 1080K
2 1 3 4 5
4-11
Preventive Maintenance
1) Replacement of the paper feed roller and the Pick-up roller
1
1
1) Remove the right cover and rear cover.
3
2) Open the copier paper feed cover. 3) Remove the paper feed cover stopper. Note: Move the stopper to the larger hole and remove.
2
2
1
1) Disconnect the harness of the paper feed unit. 2) Remove the paper feed unit (4 screws).
2
3
2 1
1) Remove the touch ring. 2) Remove paper feed roller. 3) Remove the bracket guide. 4) Remove the the pick-up roller. Note: Confirm the direction of the rollers before the installation.
4
3
4-12
2) Replacement of the DFP roller and the torque limiter
4
1) Conduct the procedure 1 and 2. 2) Remove the lower roller cover (2 screws) 3) Remove the touch ring. 4) Remove the DFP roller. 5) Remove the torque limiter. Note: Confirm the direction of the torque limiter when re-installing it. [Fit the positioning pin (rear side)]
3) Replacement of the Middle roller
5
1 3
1) Conduct the procedure 1 and 2. 2) Remove the E ring gear on middle roller. 3) Remove the touch ring and bushing. 4) Slide and remove the middle roller.
4 2
4-13
Preventive Maintenance
(3) Developer unit Item Part name 1 Cleaning blade 2 Drum 3 Blade side seal (F) 3 Blade side seal (R) 4 Corona 5 Developer 6 Spacer ring (F) 6 Spacer ring (R) 7 Toner dispersion prevention cover 8 Mag-roll stopper (F) 8 Mag-roll stopper (R) 9 Drum separation finger cycle 120K 120K 120K 120K 360K 120K 120K 120K 600K 600K 600K 360K
3 9 2 1 4 6 7 8 5
4-14
1) Replacement of the cleaning blade
1
2
1) Open the front cover. 2) Move the toner hopper to front side. 3) Pull and turn the developer release lever and release the developer unit. (Refer to p. 48 step 4)
1
2
3 1 2
5
4
1) Remove the drum unit solenoid cover (1 screw). 2) Disconnect the harness. 3) Remove the drum fixing screw. 4) Open the waste toner bottle cover and remove the bottle. 5) Remove the drum unit.
1
1) Press the tabs of the drum unit lid toward arrow mark to remove the lid.
4
2 3
1) Remove the cleaning blade tension spring. 2) Remove the blade case (1 screw). 3) Remove the cleaning blade. Note: - Before replacing the cleaning blade, put drum starting powder on the
1
drum surface and cleaning blade. (lightly and evenly) - After replacing the cleaning blade, do not forget to reinstall the tension spring.
4-15
Preventive Maintenance
3
2) Replacement of the Drum / Side seal
5
5
1) Conduct the procedure 1 and 2 and take the drum unit out. 2) Remove the drum cleaning blade tension spring (refer to P.4-13 step 4). 3) Remove the front side screw on the drum shaft. 4) Remove the drum shaft. 5) Remove the drum.
3 4
Note: Handle the case not the drum. 1) Remove the side seal (Front and Rear). 2) Clean the surface of drum unit frame then reinstall the side seal (Front and rear). 3) Replace the drum. Adjustment after replacing new drum a. Set F mode. b. Clean the copy density sensor. c. Adjust F8-14. d. Adjust copy quality. e. Go back to normal mode.
6
3)
Replacement of the charge corona 1) Conduct the same procedure 1 and 2 and take the drum unit out. 2) Remove the corona fixing screw and remove the charge corona assembly. 3) Remove the grid(3a), mylar(3b) and corona wire(3c).
2
7
3b
3a
3b
3c
4-16
4) Replacement of the developer
8
2
1) Conduct the procedure 1 and 2 2) Remove the developer unit and remove the mixer lid. 3) Dump the developer out of the unit. 4) Vacuum any developer on mag-roller and inside of the unit. 5) Remove the developer unit duct cover and clean inside of duct cover. 6) Pour in the new developer Note: - Shake the developer bottle and pour it into the developer unit evenly. - Pay attention when cleaning the TDC sensor with vacuum cleaner , TDC sensor may be damaged by electrostatics. Preventive Maintenance Adjustment after relacing new developer a. Set F mode.
5
b. Set and run F8-09. c. Write the contents of F6-21 and 26 on the memory sheet.
5)
Replacement of the spacer ring 1) Conduct the procedure 1 and 2 then remove the developer unit. 2) Remove the bias terminal (2 screws). 3) Remove the C ring and gears on mag-roller. 4) Remove the spacer ring (Rear). 5) Remove the bushing support plate (1 screw). Note: Take note of the position of the bushing support plate and reinstall it in the same position after replacing the spacer ring. 6) Remove the spacer ring (Front). 7) Replace the spacer ring (Front and rear).
4-17
9
7
1 5 2 3
6)
Replacement of the toner dispersion prevention cover/magnetic roller stopper · Conduct procedure 1 and 2 then pull out the developer unit. (1)Remove the screws (x 2).
1
10
(2)Remove the toner dispersion prevention cover. (3)Remove the magnetic roller stoppers
3
1
2
(front/rear) and replace the magnetic roller.
3
7)
Replacement of the dust collecting filter · Conduct procedure 1 and 2 then pull out the drum unit (1)Disconnect the sensor harness. (2)Remove the touch ring. (3)Slide the sensor base to rear side then
2 1 3
11
put it down and pull out.
(4)Remove the sensor PCB from under side. (5)Push the A from under side and slide the separation finger then remove it.
4
A
Note: Be careful when removing and reinstalling the drum finger that the two springs are not lost or damaged. (6)Reassemble in reverse order.
5
5
4-18
(4) Fuser unit Item Part name 1 Cleaning web roller 2 Web pressure roller 3 Fuser lamp 4 Heat roller 5 Heat roller bearing 6 Insulating bushing 7 Heat roller gear 8 Thermistor 9 Separation finger (upper) 10 Separation finger (lower) 11 Pressure roller 12 Pressure roller bearing 13 Fuser entry guide Cycle 120K 1200K 240K 360K 600K 360K 600K 240K 480K 480K 480K 600K 1200K Preventive Maintenance
4-19
9 10 11 4 8 3 5 6 7 13 12 2 1
1)
Replacement of cleaning web/web pressure roller (1) Open the front cover.
1 4a 3 5 4b 4b 5
1
2
(2) Swing the toner hopper to the right. (3) Remove the fuser unit manual paper feed knob. (1 screw reverse threaded) (4) Remove the front cover. a) Remove the band. b) Slide out the hinge pins. (5) Remove the fuser front cover (2 screws).
2
3 1
(1) Disconnect the fuser unit connector (x 2). (2) Open the two LWS (x 2). (3)Open the paper exit unit. (4)Remove the fuser bracket (3 screws).
2 1
(5) Carefully slide the fuser unit out of the front of the machine.
2 4
3
1 1
(1) Remove the web ass'y bracket screw (x 2). (2) Slide the web ass'y to the right and remove.
4
3
4
(1) Remove the bushings (2 screws) and rollers (x2). (2) Install the new web as shown. (3) Make sure to remove the slack in the supply roller. (4) Make sure the take-up drive is working normally.
1 2
4-20
2) Replacement of the fuser lamp/heat roller/heat roller bearing/insulating bushing/ heat roller gear
1
5
1
· Conduct procedure 1and 2. (1)Remove the screws (x 4) (2)Remove the heat insulating cover. Note: Either loosen pressure screws (x 2) or install fuser shipping screws (x 2).
2
6
3 2
(1)Remove the springs. 1a 1b (2)Turn the fuser lamp covers. 2a 2b
850 W
(3)Remove the fuser lamps (x2).
1
550 W
Note: The long one is the main fuser lamp. (850W) Reassemble the lamp with the rating indication in the rear. Preventive Maintenance
7
1 1 3
3 2 4
(1) (2) Remove the screws and take off the thermistor and thermostat blocks. (Lift the thermostat and slide to the front.) (3)Remove the screws (x 2). (4)Remove the roller pressure plates. (5)Remove the heat roller.
4
5
8
2
· Remove the heat roller gear, bearing and
1
insulating bushing. · Replace the heat roller. Note: After reassembling and tightening the screws of the pressure springs, check
1
the pressure roller for fit.
4-21
3) Replacement of the thermistor
9
3
· Conduct procedure 5. (3)(4) Remove the screw. (5)Remove the thermistor. · Replace the thermistor.
4
5
SV507
4) Replacement of the separation finger (upper/lower)
10
2
(1)Open the fuser exit cover.
3
(2)Remove the screws (x 2). (3)Remove the separation finger (upper) bracket.
1 2
11
2 2
(1) Remove the separation finger (upper) spring. (2) Remove the separation finger (upper). · Replace the fingers (x 5).
1
12
2
(1)Remove the screw (x1) and fuser exit cover pin then remove the exit cover. (2)Remove the screws (x 2). (3)Remove the duplex guide roller block and bracket together.
1 2
4-22
13
2
(1)Remove the spring (x 2).
2
(2)Turn the separation fingers and remove them (x 5).
1
1
SV506
5) Replacement of the pressure roller/roller bearing
14
3
· Remove the heat roller (refer to step 5 to 7). · Remove the separation finger upper/lower brackets (refer to 10 and 12). Mark the current height adjustment to use as a reference during re-assembly. (1)Remove the screws (x 2).
1 2
(2)Remove the entry guide. (3)Remove the pressure roller. · Remove the roller bearing.
4-23
Preventive Maintenance
1
(5) Optics unit Item Part name 1 Exposure lamp 2 Filte