Ricoh MP4002/5002 service manual Part 4

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Replacement and Adjustment

Rev. 09/11/2012

Exterior Covers


4.3.8 INNER TRAY

  1. Left cover ( p.4-4)

  2. Upper inner cover ( p.4-3 "Front Door, Upper and Lower Inner Cover")

  3. Paper exit cover ( p.4-8)


    image


  4. Connector cover [A]

    image

  5. Inner rear cover [A]

    image

  6. Inner tray [A]

Scanner

Rev. 09/11/2012


image

    1. SCANNER


      1. EXPOSURE GLASS

        1. Glass cover [A] (x 2)

        2. ARDF exposure glass [B]

        3. Rear scale [C] (x 3)

        4. Exposure glass with left scale [D]


          • Position the white marker [E] at the rear-left corner and the black or blue marker at the front-left corner when you reattach the ARDF exposure glass.


      2. SCANNER EXTERIOR PANELS AND OPERATION PANEL


        Operation panel

        1. Remove the Operation Panel ( 4.3.6)


        Scanner left cover


        image

        1. Scanner left cover [A] (x 3)

        Replacement and Adjustment

        Rev. 09/11/2012 Scanner


        Scanner right cover


        image

        1. Scanner right cover [A] (x 2)


        Scanner front cover

        1. Operation panel ( p.4-7)

          image

        2. Scanner front cover [A] (x 2)


        Scanner rear cover


        image

        1. Scanner rear cover [A] (x 1)

      3. LENS BLOCK ASSEMBLY

        1. Exposure glass image p.4-10)

        2. Scanner right cover imagep.4-11 "Scanner Exterior Panels and Operation Panel")


        SBU cover [A] ( x 4)

        3.

        1. Original size sensor bracket image p.4-15 "Original Size Sensor")


          image

        2. Lens block assembly [A] image x 4, Grand screw x 1, image x 2)


          image

          • Do not remove the other screws on the lens block unit.

        When reassembling

        Adjust the following SP modes after you replace the lens block assembly:

        • SP4–008 (Sub Scan Mag): image "Scanning" in "Copy Adjustments: Printing/Scanning")

        • SP4–010 (Sub Mag Reg.): image "Scanning" in "Copy Adjustments: Printing/Scanning")

        • SP4–011 (Main Scan Reg): image "Scanning" in "Copy Adjustments: Printing/Scanning")

        • SP4–688 (DF: Density Adjustment): Use this to adjust the density level if the ID of outputs made in the DF and Platen mode is different.

      4. ORIGINAL SIZE SENSOR

        1. Exposure glass with left scale imagep.4-10 "Exposure Glass")

        2. Scanner right cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

          Replacement and Adjustment

        3. SBU cover image p.4-14 "Lens Block Assembly")


          image

        4. Remove the screw [A] on the sensor board bracket.


          image

        5. Circuit chip [A] image x 1, image x 1)

          image


        6. Original size sensor bracket [A] image x 2)

          image

        7. Original size sensors [A] (hooks)

      5. EXPOSURE LAMP


        image

        • Before replacing the scanner lamp, check and note the first three digits in the bar-code on the new scanner lamp image “Chromaticity rank adjustment” in this section).

          1. Operation panel image p.4-7)

          2. Exposure glass image p.4-10)

          3. Scanner front cover image p.4-11 "Scanner Exterior Panels and Operation Panel")


            image

            Replacement and Adjustment

          4. Move the first scanner carriage [A] to the position shown above.


            image

          5. Remove the two screws on the scanner lamp [A].

            image

          6. Disconnect the connector [A] on the scanner lamp.

            image

          7. Pull out the scanner lamp [A].


          Chromaticity rank adjustment

          Each scanner lamp has a specific chromaticity rank. The chromaticity rank is indicated by the bar-code on the new scanner lamp. After replacing the lamp, adjust the chromaticity rank to correspond to the new scanner lamp.

          image

          1. Check the first three digits [A] in the bar-code on the new scanner lamp before installing the new lamp.

            Replacement and Adjustment

          2. After installing the new lamp, go to SP4-954-005 and enter the SP setting number referring to the table below.


          1st Three Digits

          SP Setting (SP4-954-005)

          1st Three Digits

          SP Setting (SP4-954-005)

          139

          3

          166

          12

          140

          2

          167

          11

          141

          1

          168

          10

          142

          6

          169

          15

          143

          5

          170

          14

          144

          4

          171

          13

          145

          9

          172

          18

          146

          8

          173

          17

          147

          7

          174

          16

          148

          12

          204

          3

          149

          11

          205

          2

          150

          10

          206

          1

          151

          15

          207

          6

          152

          14

          208

          5

          153

          13

          209

          4

          154

          18

          210

          9

          155

          17

          211

          8

          156

          16

          212

          7

          157

          3

          213

          12

          158

          2

          214

          11

          159

          1

          215

          10

          160

          6

          216

          15

          1st Three Digits

          SP Setting (SP4-954-005)

          1st Three Digits

          SP Setting (SP4-954-005)

          161

          5

          217

          14

          162

          4

          218

          13

          163

          9

          219

          18

          164

          8

          220

          17

          165

          7

          221

          16


      6. SCANNER HP SENSOR/PLATEN COVER SENSOR


        Scanner HP Sensor

        1. Scanner rear cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

        2. Exposure glass image p.4-10)

          image

        3. Move the 1st scanner carriage [A] to the right side.

          image

        4. Remove the mylar [A].

          image


        5. Remove the scanner HP sensor [A] image x 1, three snaps)


        Platen Cover Sensor

        Replacement and Adjustment

        1. Scanner rear cover image p.4-11 "Scanner Exterior Panels and Operation Panel")


          image

        2. Platen cover sensor [A] image x 1, image x 1)

      7. SCANNER MOTOR

        1. Scanner rear cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

          image

        2. Remove the 8 screws of the scanner rear frame [A].

          image

        3. Disconnect the two connectors.

          image

        4. Pull over the scanner rear stay [A] and remove it image x 2, image x 3).


          Scanner motor bracket [A] ( x 1)

          Replacement and Adjustment

          5.


          Scanner motor [A] ( x 2,

          x 1, spring x 1, belt x 1)

          6.


          image

          • After replacing the scanner motor, do the image adjustments in the following section of the manual image "Scanning" in "Copy Adjustments: Printing/Scanning").

      8. SCANNER MOTOR DRIVE BOARD

        1. Scanner rear cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

        2. Scanner rear stay. image p.4-22 "Scanner Motor")


          image

        3. SIO [A] image x 4, image x All)


      9. FRONT SCANNER WIRE

        1. Scanner front cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

        2. Scanner left cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

          image

        3. Scanner left stay [A] image x 3)

        4. Scanner left rail frame [B].

          image


          Replacement and Adjustment

        5. Operation panel stay [A] image x 5, image x 1)


          image

        6. Scanner front stay [A] image x 5)

        7. To make reassembly easy, slide the 1st scanner carriage to the right.

          image


        8. Front scanner wire clamp [A]

        9. Front scanner wire bracket [B] image x 1)

        10. Front scanner wire and scanner drive pulley [C] image x 1)


        Reassembling the Front Scanner Wire


        image

        1. Position the center ball [A] in the middle of the forked holder.

        2. Pass the right end (with the ball) [B] through the square hole. Pass the left end (with the ring) [C] through the notch.

        3. Wind the right end counterclockwise (shown from the machine’s front) five times. Wind the left end clockwise twice.

          image

          • The two red marks [D] come together when you have done this. Stick the wire to the pulley with tape. This lets you easily handle the assembly at the time of installation.

            image


        4. Install the drive pulley on the shaft [E].


          image

          Replacement and Adjustment

          • Do not attach the pulley to the shaft with the screw at this time.

        5. Insert the left end into the slit [F]. The end should go via the rear track of the left pulley [G] and the rear track of the movable pulley [H].


          image

        6. Hook the right end onto the front scanner wire bracket [I]. The end should go via the front track of the right pulley [J] and the front track of the movable pulley [K].

          image

          • Do not attach the scanner wire bracket with the screw at this time.

            image

        7. Remove the tape from the drive pulley.

        8. Insert a scanner-positioning pin [L] through the 2nd carriage hole [M] and the left holes [N] in the front rail. Insert another scanner positioning pin [O] through the 1st carriage hole [P] and the right holes in the front rail [Q].

        9. Insert two more scanner positioning pins through the holes in the rear rail.

        10. Screw the drive pulley to the shaft [R].

        11. Screw the scanner wire bracket to the front rail [S].

        12. Install the scanner wire clamp [T].

        13. Pull out the positioning pins.


          image

          • Make sure the 1st and 2nd carriages move smoothly after you remove the positioning pins. Do steps 8 through 13 again if they do not.

          • After replacing the scanner wire, do the image adjustments in the following section of the manual image "Scanning" in "Copy Adjustments: Printing/Scanning").

      10. REAR SCANNER WIRE

  1. Scanner front cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

  2. Scanner left cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

  3. Scanner left stay image p.4-24 "Front Scanner Wire")

  4. Scanner left rail frame image p.4-24 "Front Scanner Wire")

  5. Scanner rear cover image p.4-11 "Scanner Exterior Panels and Operation Panel")

  6. Scanner rear stay image p.4-22 "Scanner Motor")

    image

    Replacement and Adjustment

  7. Rear rail frame [A] image x 5)

  8. SIO image p.4-24 "Scanner Motor Drive Board")


    image


  9. To make reassembly easy, slide the first scanner to the center.

  10. Rear scanner wire clamp [B]

  11. Rear scanner wire bracket [C] image x 1)

  12. Scanner motor gear [D] image x 1)

  13. Rear scanner wire and scanner drive pulley [E] image x 1)

Reassembling the Rear Scanner Wire


image

  1. Position the center ball [B] in the middle of the forked holder.

  2. Pass the end with the ball [A] through the right square hole from the front.

  3. Position the center ball [B] in the middle of the notch, as shown by the arrow.

  4. Pass the ball end [A] through the drive pulley notch.

  5. Wind the end with the ring [C] clockwise (shown from the machine’s front) three times; wind the ball end [A] clockwise (shown from the machine’s front) five times.

    image

  6. Stick the wire to the pulley with tape, so you can easily handle the pulley and wire during installation.

  7. Install the drive pulley on the shaft.


    image

  8. Install the wire.


    image

  9. Perform steps 8 through 13 in “Reassembling the Front Scanner Wire”.


    image

    1. LASER UNIT



      image

      • Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes.

      1. CAUTION DECAL LOCATIONS

        image

        Replacement and Adjustment

        Two caution decals are located in the laser section as shown below. (See the next page for removal instructions.)


      2. LASER UNIT


        image

        1. Open the front door.

        2. Front door [A] (pins x 2)

        3. Upper inner cover [B] image x 2)

        4. Glass cap [C]

        5. Shield glass [D]

        6. Lower inner cover [E] image x 2)


          image

        7. Laser unit connectors [E] image x 3, image x 1)


          image

          • Do not disconnect the harnesses on the LD board [F] unless the LD unit has to be replaced. This board is precisely adjusted in the factory.

        8. Laser unit [G] image x 2)


          image

          • When sliding out the laser unit, do not hold the LD board. Hold the laser unit.

      3. POLYGON MIRROR MOTOR


        image

        Replacement and Adjustment

        1. Laser unit image p.4-31)

        2. Laser unit cover [A] image x 4)

        3. Polygon mirror motor [B] image x 4, image x 1)

        4. After replacing the polygon mirror motor, do the image adjustment image p.4-108 "Copy Adjustments: Printing/Scanning").

      4. LASER SYNCHRONIZATION DETECTOR

        1. Laser unit image p.4-31)


          image

        2. Laser synchronization detector [A] image x1, image x1)

      5. LD UNIT

        1. Laser unit image p.4-31)

          image

        2. Upper spring plate [A] image x 1)

        3. Lower spring plate [B] image x 1)

        4. LD unit [C] image x 1, image x1, spring x 1)


          image

          • To avoid damaging the LD board, hold it securely when disconnecting the connectors. Hold the laser unit casing.

        5. After replacing the LD board, do the "Laser Beam Pitch Adjustment" (described in the following section). Keep the lower inner cover removed before doing this adjustment because you need to adjust the adjustor screw [D] on the LD unit with a screwdriver.


        Laser Beam Pitch Adjustment


        image

        1. Install a (new) LD unit [A] with the left side of the LD unit being lower than the right side. (This makes this adjustment easier.)

        2. Print the test pattern "Hounds Tooth Check (2-Dot Horizontal)" (No. 16 in SP2109-001).

        3. Check if the vertical stripes appear on the second pattern (counted from the leading edge) of the printout.

          • Correct: No vertical stripes appear (see the sample following this procedure.)

          • Wrong: Vertical stripes appear (see the sample following this procedure.)

        4. Turn the adjustor screw [B] by 90 degrees clockwise (counterclockwise).


          image

          • If the image of the printout is getting worse, try reverse rotation (clockwise image counterclockwise)

        5. Print the test pattern and check it out.

        6. Try steps 2 to 4 again until you get an image with no vertical stripes.

        7. Reassemble the machine after completing this adjustment.

        Replacement and Adjustment

        Correct: No vertical stripes appear


        image

        Incorrect: Vertical stripes appear


        image

    1. PCDU


      1. PCDU (PHOTOCONDUCTOR AND DEVELOPMENT UNIT)

        1. Open the front door.


          image

          Replacement and Adjustment

        2. Open the right door [A].

        3. Release the lock lever [B].

        4. Pull out the PCDU [C] and place it on a clean flat surface.

        5. Spread a large piece of paper on a flat surface.


          image

          • Make sure the area is free of pins, paper clips, staples, etc. to avoid attraction to the magnetic development roller.


        Reinstallation

        Open the right cover before you install the PCDU in the machine.

      2. DRUM

        1. Remove the PCDU image p.4-37)


          image

        2. Toner cap [A]

        3. Insert cap [A] into the opening of the PCDU [B].


          image

          • Make sure that the cap is inserted completely into the opening.


            image

        4. Open the PCDU [C] image x 2).


          image

        5. Bracket [D] image x 1)


          image


          image

        6. Pull the drum [E] towards the front image (the left side in the illustration) while releasing the charge roller [F] using the release levers image [G], and then remove the drum image.


          Replacement and Adjustment

          • Never touch the drum surface with bare hands.


        Re-installation

        1. Replace the drum and close the PCDU image x 2).

        2. Put the opening cap [A in the previous procedure] back in its original place.

        3. After replacing the drum, do these SPs:

          • SP 2001: Charge Bias Setting – make sure that this is at the default setting

          • SP 3001-2: P Sensor Initial Setting (P sensor = ID Sensor)

          • SP 2805: Process Setting

          • SP 2810-1: Grayscale Setting

      3. PICK-OFF PAWLS

        1. Drum image p.4-38)


        image

        1. Pawl assembly [A]

        2. Pick-off pawl [B] (spring x 1, spur x 1)


        Pick-off Pawl Position Adjustment

        If the pick-off pawl has marked the drum with a line, the pick-off pawl position can be adjusted using either method:

        • Changing the spur position

        • Changing the pick-off pawl assembly position

      4. CHARGE ROLLER AND CLEANING ROLLER

        1. Drum image p.4-38)

        image

        Replacement and Adjustment

        1. Push the charge roller holder [A] toward the front of the drum image x 2) and remove the spring [B].

        2. Charge roller [C].


          image

          • Disengage the charge roller on the right side to remove it. Try to avoid touching the charge roller.

        3. Cleaning roller [D]


          image

          • Disengage the cleaning roller on the left to remove it.

        4. After replacing the charge roller and cleaning roller, check the value of SP2001-001. If it is not at the standard value (1500), set SP2001-001 to "1500".

          image

          • If this is not done, the carrier will be attracted to the drum because the charge roller voltage will be too high.

      5. DRUM CLEANING BLADE

        1. Drum image p.4-38)

        1. Charge roller and cleaning roller image p.4-41)


          image

        2. Remove drum cleaning blade [A] image x 2)


        Re-installation

        Put toner on the edge of cleaning blade and the mylar at the back side of cleaning blade before re-installing this blade.

      6. ID SENSOR

        1. PCDU image p.4-37)

        1. Fusing unit image p.4-61)


          image

          Replacement and Adjustment

        2. ID sensor bracket [A] image x 2, image x 1)

        3. ID sensor [B] image x 1)


          image

          • Do SP3-001-002 to initialize the ID sensor after replacing.

    2. DEVELOPMENT


      1. DEVELOPMENT FILTER

        1. PCDU image p.4-37)

        1. Open the PCDU. image p.4-38 "Drum")

          image

        2. Upper development cover [A] image x2)

        3. Development filter [B]


      2. DEVELOPMENT ROLLER

        1. PCDU image p.4-37)

        1. Open the PCDU. image p.4-38 "Drum")

        2. Upper development cover image p.4-44 "Development Filter")


          image

        3. Development roller [A]


          image

          • Work carefully to avoid scratching or nicking the development roller.

        Cleaning Procedure

        1. PCDU image p.4-37)


        image

        Replacement and Adjustment

        1. Remove the two screws [A] and open the PCDU as shown above.


          image

        2. Remove the upper development cover [A] image x 2).


          image

        3. Fold up a sheet of copy paper [A] to fit the width of the uncovered area of the development roller, as shown below.

        4. Slide the paper [A] along the length of the roller to clean the toner off the surface.

          image

        5. Rotate the development roller [A] in the direction of the arrow until the section you cleaned is no longer visible.

        6. Repeat steps 5 and 6 until you have cleaned the entire surface of the roller.

        7. Reassemble the PCDU and install the PCDU into the machine.


      3. DEVELOPER

        1. PCDU image p.4-37)

        1. Open the PCDU. image p.4-38 "Drum")

        2. Development roller image p.4-44)

          image

        3. Joint bracket [A] image x 2, image x 1)

        4. Development unit [B]

          image

        5. Tip out the old developer [C].

        6. Turn drive gear [D] to ensure that no developer remains in the unit or on the developer roller.

          image

          Replacement and Adjustment

          • Dispose of the used developer in accordance with local regulations. Work carefully to avoid scratching or nicking the development roller.

        7. Clean the development roller with a dry cloth.


          image


        8. Pour approximately 1/3 of the developer [E] evenly along the length of the development unit.

        9. Rotate the drive gear [F] to work the developer into the unit.

        10. Repeat steps 8 and 9 until all toner is in the unit and level with the edges.

        11. Re-install the development roller.


          image

          • Make sure that the seals at the both sides of the development roller are set inside the case after you re-install the development roller.

            image

        12. Place a piece of paper [G] over the toner entrance hole. This prevents used toner falling from the drum into the development unit during the TD sensor initial setting and interfering with the Vref setting (toner density reference voltage)

        13. Secure the drum [H] to the development unit, to close the PCDU image x 2).

        14. Install the PCDU in the machine and close the front and right doors.

        15. Turn on the main power switch, and wait for the machine to warm up.

        16. Do SP2801 to initialize the TD sensor and enter the developer lot number.

        17. After performing the TD sensor initial setting, remove the sheet of paper from the PCDU.

      4. TD SENSOR

        1. PCDU image p.4-37)

        1. Empty all developer from the development unit. image p.4-46 "Developer")

          image

          Replacement and Adjustment

        2. Seal

        3. TD sensor [A] image x1)


          image

          • The TD sensor is attached to the casing with double-sided tape [B]. Pry it off with the flat head of a screwdriver. Use fresh double-sided tape to re-attach the sensor.

        4. Pour new developer into the development unit and perform the TD sensor initial setting using SP2-801.

          image

          • When performing the TD sensor initial setting, cover the toner entrance hole with a piece of paper.

    3. TRANSFER


      1. TRANSFER BELT UNIT


        image

        • To avoid exposing the drum to strong light, cover it with paper if the right cover will be open for a long period.


          image

          1. Open the right door [A].

          2. Release the lever [B].

          3. Transfer belt unit [C]


            image

            • Avoid touching the transfer belt surface.

      2. TRANSFER BELT

        1. Transfer belt unit image p.4-50)


          image

          Replacement and Adjustment

        2. Connector [A] image x 1)


          image

        3. Remove the springs (front and rear) [B].

        4. Release the hooks (front and rear) [C].

        5. Transfer belt with rollers [D]

          image


        6. Lay the transfer belt with rollers on a flat clean surface, and fold the unit [E] to release the tension on the belt image x 2).

          image

        7. Transfer belt [F]


          image

          • Avoid touching the transfer belt surface.

          • Before installing the new transfer belt, clean all the rollers and shafts with alcohol to prevent the belt from slipping.

          • When reinstalling the transfer belt, make sure that the belt is under the pin [F].

          • To avoid damaging the transfer belt during installation, manually turn the rollers and make sure that the new transfer belt is not running over the edges of any of the rollers.

      3. TONER OVERFLOW SENSOR

        1. Transfer belt unit image p.4-50)

          image

        2. Toner overflow sensor [A] image x 1, image x 1)


        Replacement and Adjustment

      4. TRANSFER BELT CLEANING BLADE/TONER OVERFLOW SENSOR

        Transfer Belt Cleaning Blade

        1. Transfer belt unit image p.4-50)

        2. Transfer belt image p.4-51)


          image


        3. Transfer belt cleaning blade [A] image x 2)


          image

          • Avoid touching the edge of the new blade. Check the new blade for dust or damage.

        Toner Overflow Sensor

        1. Transfer belt unit image p.4-50)

          image

        2. Toner overflow sensor [A] image x 1, image x 1)

    4. PAPER FEED


      1. PAPER FEED UNIT


        Tray 1 and Tray 2

        1. Right rear cover image p.4-5)

        2. Duplex unit image p.4-75)

        3. Pull out tray 1 and tray 2.

          image

        4. Paper guide plate [A] (hook x 2)


        Harness cover [A] ( x 1)

        Replacement and Adjustment

        5.

        image


        6. Paper feed unit [A] image x 2, image x 1)


      2. PICK-UP, FEED AND SEPARATION ROLLERS


        Tray 1 and Tray 2

        1. Paper feed unit image p.4-55 "Paper Feed Unit")


          image

        2. Roller holder [A] image x 1)

        3. Pick-up roller [B]

        4. Feed roller [C]

        5. Separation roller [D] and torque limiter [E] image x 1)

      3. TRAY LIFT MOTOR

        1. Rear cover image p.4-4)


          image

          Replacement and Adjustment

        2. Tray lift motor 1 or 2 [A] image x 2, image x 3)

      4. RELAY, TRAY LIFT, PAPER END AND PAPER FEED SENSORS

        Tray 1 and Tray 2

        1. Right rear cover image p.4-5)

        2. Duplex unit image p.4-75)

        3. Paper feed unit image p.4-55)

          image

        4. Tray lift sensor [A] image x 1)

        5. Paper end feeler [B] and paper end sensor [C] (hook, image x 1 each)

        6. Relay sensor bracket [D] image x 1)

        7. Relay sensor [E] image x 1, hook)

        8. Paper feed sensor bracket [F] image x 1)

        9. Paper feed sensor [G] image x 1, hook)

      5. REGISTRATION SENSOR

  1. Right rear cover image p.4-5)

  2. Duplex unit image p.4-75)

  3. Paper feed unit for tray 1 image p.4-55 "Paper Feed Unit")

  4. Paper Trays 1 and 2

    image

    Replacement and Adjustment

  5. Paper dust box [A]


    image

  6. Open the front door.

  7. Pull out the paper dust container [B].

  8. Remove two screws [C].

    image

  9. Dust container rail [F] image [E] x 1)

  10. Sensor bracket [G] image x 1)


    image

  11. Registration sensor [H] image x 1, hooks)


Reinstall the registration sensor

It is very difficult to secure the sensor bracket to the frame. First attach the sensor bracket with tape temporarily.

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