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Ricoh FT5034 Service Manual

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SERVICE MANUAL
FT5034C

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Summary of Contents for Ricoh FT5034

  • Page 1 SERVICE MANUAL FT5034C...

  • Page 2: Table Of Contents

    CONTENTS 1. INSTALLATION............ 2. OVERVIEW............3. COPY PROCESS ..........11 4. SECTION DESCRIPTIONS ........13 5. SP MODE/DIP SW TABLE........92 6. CALL SERVICE CONDITIONS ......98 7. PREVENTIVE MAINTENANCE ......105 8. TROUBLESHOOTING..........114 9. ELECTRICAL DATA - 1 -...

  • Page 3: Installation

    1. INSTALLATION 1.1 INSTALLATION REQUIREMENTS....3 1.2 INSTALLATION PROCEDURE......4 - 2 -...
  • Page 4 1.1 INSTALLATION REQUIREMENTS The installation location should be carefully chosen because environmental conditions greatly affect the performance of a copier. 1. Environments to Avoid • Avoid any area exposed to direct sunlight or strong light (Illumination must be less than 1500 Lux). •...
  • Page 5 1.2 INSTALLATION PROCEDURE NOTE: 1. When lifting and moving the copier, grasp the black painted stays on each side as shown. 2. When the optional sorter is installed, the above mentioned stays can not be held. Wear gloves to protect hands from the edges of the copier base plate.
  • Page 6 2. Developer Supply Place a clean sheet of paper on your work surface. 1. Raise the development lock lever and pull out the development unit. Place the unit on a clean sheet of paper. 2. Separate the toner tank from the Toner Tank development unit (2 screws).
  • Page 7 5. Perform the Drum Conditioning (This operation must be performed after Drum Conditioning developer and drum installation.) Switch 1. Open the front right cover and move the drum conditioning switch on the reverse side of the operation panel to the left. Close the front right cover and switch the power on.

  • Page 8: Overview

    2. OVERVIEW 2.1 SPECIFICATIONS ..........8 2.2 GUIDE TO COMPONENTS ........9 - 7 -...
  • Page 9 2.1 SPECIFICATIONS Items Specifications Remarks Configuration Desk top Copy Process Dry electrostatic transfer system Originals Sheet/book Original Size Maximum A3 Copy Paper Size Maximum A3, Minimum A6 Lengthwise Copy Paper Weight 52 g/m ~ 157 g/m F/L cassette: 64 ~ 90 g/m 1st &...
  • Page 10 2.2 GUIDE TO COMPONENTS 1. Operation Panel - 9 -...
  • Page 11 2. Indicator Panel - 10 -...

  • Page 12: Copy Process

    3. COPY PROCESS 3.1 COPY PROCESS DIAGRAM ......12 - 11 -...
  • Page 13 3.1 COPY PROCESS DIAGRAM Charge Corona Unit Exposure Quenching Erase Lamp Lamp Carrier Toner F TYPE Cleaning Blade Development Photoconductor Drum Roller Cleaning Brush Pre-Cleaning Corona (PCC) ID Sensor Pre-Transfer Lamp Pick-off Pawls Paper Transfer Corona Wire Separation Corona Wire 1.

  • Page 14: Section Descriptions

    4. SECTION DESCRIPTIONS 4.1 MECHANICAL COMPONENT LAYOUT ....14 4.2 DRIVE LAYOUT (INCLUDING PERIPHERALS) ......15 4.3 ELECTRICAL COMPONENT LAYOUT .....16 4.4 PAPER FEED AND REGISTRATION ....18 4.5 OPTICS...............28 4.6 AROUND THE DRUM ........44 4.7 DEVELOPMENT AND TONER SUPPLY ...50 4.8 ID SENSOR AND PTL........62 4.9 IMAGE TRANSFER, PAPER SEPARATION AND PAPER TRANSPORT........71 4.10 CLEANING ............75...

  • Page 15: Mechanical Component Layout

    4.1 MECHANICAL COMPONENT LAYOUT 1. 3rd Mirror 19. 4th Mirror 2. 2nd Mirror 20. Feed Roller (By-pass Feed) 3. 1st Mirror 21. Toner Tank 4. Exposure Lamp 22. Pick-up Roller 5. Exposure Glass 23. Pressure Lever 6. Hot Roller Stripper 24.

  • Page 16: Drive Layout (Including Peripherals)

    4.2 DRIVE LAYOUT (INCLUDING PERIPHERALS) 9 10 1. DF Feed-out Roller 17. Sorter Adapter Drive Belt 2. Feed-out Roller Drive Belt 18. Fusing Exit Roller Gear 3. Pulse Generator Sprocket/Toner 19. Fusing Drive Release Gear Supply Drive Gear 20. Transport/Fusing Drive Sprocket →...

  • Page 17: Electrical Component Layout

    4.3 ELECTRICAL COMPONENT LAYOUT 1. Scanner Motor 21. Lamp Regulator Board 2. By-pass Feed Clutch 22. Power Transformer 3. Pulse Generator Sensor 23. Main Fuse 4. 1st Cassette Paper End Sensor 24. Fusing Control Board 5. By-pass Pick-up Solenoid 25. Noise Filter 6.
  • Page 18 39. Exposure Lamp 50. 1st Cassette Paper Size Sensor 40. Thermofuse 51. By-pass Table Sensor 41. Fusing Exit Sensor 52. By-pass Paper End Sensor 42. Fusing Thermistor 53. Optics Cooling Fan 43. Main Motor 54. Drum Heater 44. Vacuum Fan 55.

  • Page 19: Paper Feed And Registration

    4.4 PAPER FEED AND REGISTRATION 4.4.1 Mechanical Parts 1. Overview In total this machine has four feed stations. They are three cassette feed stations and a by-pass feed station. The 1st and 2nd feed stations each use a size adjustable cassette, but the 3rd feed station located inside the copier uses only an A3 cassette.
  • Page 20 3. Paper End Detection and Paper Size Detection 1) Paper End Detection This machine uses a photointerrupter sensor for paper end detection. The paper end actuator, which is on the same shaft as the paper end feeler, pivots into the sensor. 2) Paper Size Detection Paper Size Sensor Paper size is detected by an array of five...
  • Page 21 4. Paper Lift Mechanism When a cassette is inserted into the copier, the Cassette Arm curved release guides on the sides of the cassette press against the rollers on the Release Guide release levers and force the release levers down. The release levers rotate the cassette arm shaft, moving the cassette arm down and out of the way.
  • Page 22 1) Registration Standard The registration standard is 0 ± 2mm. If it is 0 mm, the paper lead edge and original lead edge is the same. But due to lead edge erase, the copy image has a blank margin (3.5 ± 2.5 mm). Copy (A4) Original (A4) a: lead edge erase (3.5 ±...
  • Page 23 When paper is loaded onto the by-pass feed table, the paper end sensor is de-actuated and Start key turns green. When the Start key is pressed, the pick-up roller is lowered by the by-pass pick-up solenoid to contact the paper stack. When the paper reaches the feed roller, the pick-up roller moves up away from the paper stack.
  • Page 24 8. Electrical Control Main Control Board Signal Scan Signal CN NO. Signal Level T0 → 1st feed station Size 1 102–24B Detection: 5 V Size 2 102–22A size detection → 1st feed station No detection: 0 V Size 3 102–24A paper end Size 4 102–22B...
  • Page 25 2. By-pass Feed Table Replacement Upper By-pass Feed Guide Plate 1. Open the by-pass feed table and remove the by-pass feed table hinges from the positioning pins by pressing them inward. 2. Remove the by-pass feed table. By-pass Feed Table 3.
  • Page 26 Friction Pad Friction Eccentric 2. 1st and 2nd Feed Stations Pad Positioning Pad Holder 1) Remove the feed roller and hub (1 Mechanism snap ring). NOTE: When reinstalling the feed roller, make sure that the hub is positioned toward the rear on the shaft.
  • Page 27 Eccentric Cam 5. Mark the position of the eccentric cam Friction Pad Holder groove on the friction pad holder. 6. Remove the friction pad holder from the Holder Bracket holder bracket (1 screw and 1 eccentric cam). 7. Peel off the entrance mylar and the friction pad and stick new ones on the friction pad holder.
  • Page 28 5. Friction Pad Pressure Adjustment NOTE: This adjustment is required when multifeeds or misfeeds occur with the customer’s brand of paper. If replacement of the feed roller and the friction pad does not solve the problem, do the following adjustment. 1.

  • Page 29: Optics

    4.5 OPTICS 4.5.1 Mechanical Parts 1. Overview Exposure Lamp Reflector 2nd Mirror 4th Mirror 1st Mirror Lens 3rd Mirror Toner Shield Glass During the copy cycle, an image of the original is reflected onto the drum surface via the optics assembly as follows. Light path: Exposure Lamp →...
  • Page 30 This model uses a dc servomotor to drive the scanners. The scanner motor changes the scanner speed depending on the reproduction ratio. 3. Lens/Mirror Positioning Lens Home The lens motor (a stepping motor) changes the Lens Drive Wire Position Sensor lens and 2nd scanner position in accordance Lens Drive with the selected reproduction ratio to provide...
  • Page 31 2. Light Shading Mechanism The machine is designed so that the intensity of the light across the drum is uniform at 100% reproduction. However, the intensity of the light striking the drum tends to increase toward the edges when the reproduction ratio is decreased, as a result of the change in position of the lens.
  • Page 32 When the second scanner moves from enlargement to reduction or from reduction to enlargement, it does not move to the home position. NOTE 1) When the zoom key is pressed, the buzzer rings at reproduction ratios between 50 ~ 155% but does not ring at 156 ~ 200% and the speed of the reproduction ratio indicator is higher.
  • Page 33 4. Automatic Image Density Sensing (ADS) This copier has an ADS system for good quality copy images. Light from the exposure lamp is reflected from the original and travels to the ADS sensor on the lens base via the mirror. Sampling starts 3 millimeters from the leading edge of the original in full size mode.
  • Page 34 Manual image ADS mode Drum temperature: 30°C density mode : Development bias voltage level V: Lamp voltage –4 : ADS input voltage ~ 1.65 1.65~2.16 2.16~2.65 is the voltage of the lamp at 2.65 ~ the manual image density level 2.) 2) Function of DPS102 on the Main Board •...
  • Page 35 4.5.2 Replacement and Adjustment Left Scale 1. Exposure Glass Removal 1. Take off the left scale (2 short screws). Exposure Glass 2. Grasp the left edge of the exposure glass and lift it up slightly. Slide the other edge out from under the right glass holder. Remove the exposure glass.
  • Page 36 3. Exposure Lamp Positioning CAUTION: Be sure that the main switch is turned off before adjustment. Reflector Cover 1. Remove the exposure glass. Adjusting Screw 2. To correct the position of the filament in parallel with the sight hole, turn the Exposure adjusting screw.
  • Page 37 3. Take off the protective sheet only at both ends of the mirror. 4. Check that the rear spring plate is set properly. 5. Insert the mirror into the front side plate cut out and set it on the rear spring plate properly.
  • Page 38 10. Position the rear spring plate and hold it with your finger while inserting the mirror into the rear spring plate through the hole in the front of the scanner. NOTE: 1. Install the mirror with the reflecting surface uppermost. 2.
  • Page 39 6. Scanner Drive Wire Replacement Wire Clamp Damper Wheel Scanner Drive Wire Tension Spring 1. Turn off the main switch. 2. Remove the platen cover, the mounting studs, and the top cover. 3. Remove the left scale (2 short screws) and the exposure glass. 4.
  • Page 40 (2nd Scanner Pulley) Wire Clamp Scanner Drive Pulley Damper Wheel Bead 2) Long End 1) Short End 11. Run the scanner drive wire over the pulleys in the following order. 1) Attach the tension spring to the short end eyelet and hook the other end of spring to the cut out in the optics frame temporarily.
  • Page 41 7. Wire Clamp Positioning When the second scanner is 52 mm from the left optics frame, secure the first scanner wire clamp so that its end is positioned about 1 mm inside the home position sensor. When the copy image is enlarged, move the wire clamp to the left, and when the copy image is reduced, move the wire clamp to the right.
  • Page 42 9. Lens Motor Replacement 1. Remove the fusing unit and the left inner Wire Saddle cover (2 screws). Lens Motor Harness 2. Remove the rear cover (3 screws) and lower the main board bracket (2 screws). 3. Disconnect the lens motor connector (yellow) and free the harness from the wire saddle.
  • Page 43 12. Remove the lens motor cover from the motor assembly (1 screw). 13. Remove the lens motor from the bracket (2 screws). 14. Install the new motor on the motor bracket and reassemble the copier. 10. Light Intensity Adjustment (Exposure Lamp Voltage Adjustment) NOTE: a.
  • Page 44 11. ADS Voltage Adjustment NOTE: 1. ADS voltage adjustment is required in the following cases. 1) Exposure lamp voltage adjustment. 2) Exposure lamp replacement. 3) When using ADS mode, abnormal copy image appears. 4) Main board replacement. 1. Place more then 5 sheets of A3 paper on the exposure glass. 2.

  • Page 45: Around The Drum

    4.6 AROUND THE DRUM 4.6.1 Mechanical Parts 1. Overview The drum drive belt turns the drum pulley when the main motor is on. The rear drum flange is secured by a screw on the drum shaft and the drum spring presses the drum onto the rear drum flange.
  • Page 46 3. Erase Lamp The erase lamp illuminates the area of the charged drum surface that will not be used for the copy image. The erase lamp reduces toner consumption and the drum cleaning load. Erase Unit Charged Area Charge Corona Unit Original Lead Edge Front Endblock Cover...
  • Page 47 1. Lead Edge Erase The entire line of LEDs turns on when the main motor turns on. They stay on until the erase margin slightly overlaps the lead edge of the original image area on the drum (Lead Edge Erase Margin). This prevents the toner density sensor pattern from being developed on every copy cycle and prevents the edge of the original from appearing on the copy image.
  • Page 48 4. Erase Data • Cassette Data (0: off, 1: on) Cassette Size A4 Lengthwise B5 Lengthwise A5 Lengthwise B6 Lengthwise • Reproduction Ratio Data (0: off, 1: on) Ratio (%) 50 ~ 53 54 ~ 57 58 ~ 60 61 ~ 63 64 ~ 67 68 ~ 70 71 ~ 72...
  • Page 49 4. QL and PTL Quenching Lamp In preparation for the next copy cycle, light from the quenching lamp neutralizes any latent image charge remaining on the drum. The cold cathode lamp used for quenching is similar to the PTL; however, the light intensity of the QL is slightly less than that of the PTL.
  • Page 50 6. Drum Section Timing (For the 1st feed station, A4) Main Switch Start Key Blade Solenoid Erase Lamp QL/PTL Bias • 1st Feed MC Charge Corona Scanner ID Sensor LED Pick-off Pawl Solenoid Toner Supply Clutch Fusing Exit Sensor T1: When the Start key turns on, the QL, PTL, and Erase lamp light. T2: The charge corona turns on 0.68 second after the Start key is pressed.

  • Page 51: Development And Toner Supply

    4.7 DEVELOPMENT AND TONER SUPPLY SECTION 4.7.1 Overview Negatively charged toner is attracted to the positively charged areas of the drum, developing the latent image. The negative triboelectric charge on toner particles is generated by friction between the carrier and toner particles. Doctor Blade Permanent Magnet Paddle Roller...
  • Page 52 2. Cross Mixing This copier uses a standard cross mixing Mixing Vanes mechanism to keep the toner and developer Doctor Blade evenly mixed. It also helps agitate the Backspill Plate developer to prevent clumping and helps create the triboelectric charge. The developer on the turning development roller is split into two parts by the doctor blade.
  • Page 53 4. Bias The charge on the drum surface is dissipated in direct proportion to the intensity of the reflected light from the original. As the light intensity corresponding to the dark areas of the image is weak, the drum potential remains.
  • Page 54 c. Drum Temperature Compensation (TH2) The CPU changes the bias voltage to compensate for variations in drum sensitivity that are induced by Bias temperature changes in the drum voltage cavity. Drum The compensation is effective from 5 Base Level degrees to 50 degrees (Celsius). 5°C ~ 15°C: 14 V/1°C 15°C ~ 50°C: 6 V/1°C...
  • Page 55 CAUTION: When performing a demonstration or during PM, make sure that the main switch is not turned on and off repeatedly. 2. Bias Measurement The bias voltage can be measured by directly measuring the development roller shaft using a digital multimeter, and checking the monitor using the input check mode.
  • Page 56 (Example) non image area image area Bias for ID Sensor Pattern Drum Temp = 30°C Rest Time = Over 2 hours for image Manual ID Level Copy Cycle 5. Toner Supply Mechanism Toner Supply Toner Agitator If the toner density is detected too low through Drive Gear Toner Supply the ID sensor, the toner supply clutch is turned...
  • Page 57 DPS 101 TONER MODE DENSITY 3.5% NORMAL FREE RUN SP MODE C MODE 10.5% HIGH NORMAL NORMAL P MODE HIGHER 7. Toner End Detection The CPU uses the image density sensor to detect a toner end condition. The toner end condition is reset by opening the front cover for more than five seconds. If Vsp becomes greater than 0.8 volt twice, the CPU starts blinking the Add Toner indicator.
  • Page 58 8. Timing Main Switch Start Key Blade Solenoid Erase Lamp QL/PTL Bias • 1st Feed MC Charge Corona Scanner ID Sensor LED Pick-off Pawl Solenoid Toner Supply Clutch Fusing Exit Sensor T1: When the Start key is pressed, the bias turns on after 0.13 second. The bias voltage is constant (at the non-image area level) regardless of manual ID level.
  • Page 59 9. Bias Voltage 1. Bias Control Signals and Output Voltage (without Temperature Compensation) Output CN101-B18 CN101-B19 CN101-A18 CN101-A19 Notch Bias 4 Bias 3 Bias 2 Bias 1 3 ~ 6 2.6 ~ 2.16 ~ 2.6 1.65 ~ 2.16 ~ 1.65 2.
  • Page 60 DPS101 No 5 No 6 Toner Density Bias Voltage Normal 470 V 440 V High 500 V Higher 530 V The ID sensor bias can be changed using DIP SW101-5 and -6 to adjust the overall image density. • By SP mode (34), the bias voltage can be increased by +90 volts. 4.7.3 Replacement and Adjustment NOTE: When removing or reinstalling the development unit, apply force towards the right side to avoid scratching the drum.
  • Page 61 3. Remove the development brush cover (2 Development screws). Brush Cover 4. Set the development unit on a large sheet of paper with the unit’s inlet facing downward. 5. Turn the paddle roller knob counterclockwise. The developer will fall out onto the paper. 6.
  • Page 62 2. Toner Supply Clutch Replacement 1. Remove the rear cover (3 screws). 2. Lower the main board bracket (2 screws). 3. Remove the pulse generator assembly (1 screw). 4. Remove the toner supply clutch stopper (3 screws), the registration clutch stopper (1 screw), and the development drive support bracket (3 screws, 1 E-ring, and 1 nylon clamp).

  • Page 63: Id Sensor And Ptl

    4.8 ID SENSOR AND PTL 4.8.1 Mechanical Parts 1. Overview Drum ID Sensor ID Sensor Pre-Transfer Lamp This machine checks toner density using an ID Original sensor. After the sensor pattern is developed, its reflectivity is checked by the image density sensor.
  • Page 64 2. Toner Density Control Original Lead Edge Sensor Pattern Original Leading Edge Erase Full Erase Full Erase A5 Lengthwise Enough Toner Low Toner [Low Toner] Developed Sensor [Enough Toner] Pattern Image Image Density Sensor The main CPU checks toner density by directly detecting the image density at the beginning of the first copy cycle after the main switch is turned on, and at every 10th copy after that.
  • Page 65 [Timing chart] 3. ID Sensor Output Vsg is the ID sensor output corresponding to the drum surface erased by the erase lamp prior to the ID sensor pattern. Vsg is almost constant. Vsp is the ID sensor output corresponding to the sensor pattern image. Vsp represents the toner density of the developer because it indicates the reflected light intensity from the sensor pattern.
  • Page 66 1. Normal Toner Density (Vsg: 4 V) Vsp is about 1/8 Vsg (=0.5 V) in the normal toner density condition. 2. Low Toner Density (Vsg: 4 V) If the toner density is low, the ID sensor pattern image on the drum is dimmed. Consequently, Vsp is higher and the toner is (Normal) supplied until the next ID sensor check cycle...
  • Page 67 4. Vsp Variation The following diagram shows the variation factors which affect Vsp and their results. <Variation Factor> <Image Density> <Vsp> <Toner Supply> <Toner Density> <Vsp Image Density> (low) light high supplied high return to the 1. Charge original condition (high) dark no supplied...
  • Page 68 2. The toner supply control can be changed to C-Mode (fixed supply) or P-Mode (detect supply) by SP mode (30). The toner supply ratio is changed by the combined settings of DPS101-3, 4. The default is 30% in P-mode. DPS101 Toner MODE Density...
  • Page 69 5. Timing Main Switch Start Key Blade Solenoid Erase Lamp QL/PTL Bias • 1st Feed MC T/S Charge Scanner ID Sensor LED Pick-off Pawl Solenoid Toner Supply Clutch Fusing Exit Sensor T1: When the Start key is pressed, the PTL and erase lamp turn on. The PTL turns off 0.12 second after the fusing exit sensor turns off.
  • Page 70 4.8.2 Replacement and Adjustment 1. ID Sensor Replacement 1. Turn off the main switch. 2. Open the front cover. ID Sensor 3. Slide out the ID sensor. 4. Clean the ID sensor with a blower brush. Registration Clutch Stopper 2. PTL Replacement 1.
  • Page 71 4. ID Sensor Vsg Adjustment CAUTION: • If Vsg is not adjusted, it causes toner density control to malfunction. • Vsg must be adjusted in the following cases: 1. Main PCB replacement 2. ID sensor replacement 3. Drum replacement 4. Toner density control malfunction (Toner density high or low) Adjustment standard = 4 ±...

  • Page 72: Image Transfer, Paper Separation And Paper Transport

    4.9 IMAGE TRANSFER, PAPER SEPARATION AND PAPER TRANSPORT 4.9.1 Overview A high positive voltage is applied to the transfer corona wire, and the corona wire generates positive ions. These positive ions are applied to the copy paper, and the positive charge attracts the negatively charged toner away from the drum and onto the paper.
  • Page 73 2. T/S Corona Unit Release Lever T/S Corona Unit Release Lever When the paper misfeed occurs, lower the T/S corona unit as shown for easy paper removal. T/S Corona The T/S corona unit is secured to the guide rail Unit bracket with a screw to prevent the corona unit from coming out when lowering and raising it.
  • Page 74 4.9.3 Replacement and Adjustment 1. T/S Corona Wire Replacement Separation Corona Paper Corona Wire 1. Open the front cover. Front Endblock Guide Cover Rear 2. Remove the screw securing T/S corona Endblock unit. Cover 3. Lower the T/S corona unit and slide it out. 4.
  • Page 75 13. Remove the front of the transport unit as shown (1 E-ring, 1 spring, and 1 shaft). 14. Pull the right transport wheel and belt to the right and remove the transport wheel. 15. Remove the transport belt. - 74 -...

  • Page 76: Cleaning

    4.10 DRUM CLEANING 1. Overview Cleaning Blade Drum cleaning is accomplished by the pre-cleaning corona (PCC), cleaning brush, and cleaning blade. Cleaning Brush As the region of the drum with toner still Blade attached enters the cleaning unit, the PCC Scraper Point of Contact applies a positive charge, and the charge on...
  • Page 77 The PCC prevents this problem. As the region Cleaning Blade of the drum with toner still attached moves into the cleaning unit, the PCC applies a positive charge, and the charge on the toner is changed from negative to positive. Since like charges Cleaning repel, it is much easier for the cleaning blade to Brush...
  • Page 78 4. Cleaning Blade The cleaning pressure mechanism is shown to Stepped Bushing the right. When the cleaning solenoid is energized, it turns the cleaning solenoid lever clockwise (rear view). Due to the pull of the cleaning blade pressure spring, the pressure arm also turns clockwise and pushes the cleaning blade lever up.
  • Page 79 5. Pick-off Mechanism - Touch and Release Mechanism - Pawl Spring The pick-off solenoid energizes just after the Pawl Shaft registration rollers turn on. The pick-off lever rotates counterclockwise (rear view) and Pick-off Lever pushes the pawl shaft pin. Then the pawl shaft rotates clockwise and the pick-off pawls touch the drum.
  • Page 80 6. Timing Main Switch Start Key Blade Solenoid Erase Lamp QL/PTL Bias • 1st Feed MC Charge Corona Scanner ID Sensor LED Pick-off Pawl Solenoid Toner Supply Clutch Fusing Exit Sensor T1: When the main switch is turned on, the blade solenoid turns on. The blade releases 15 minutes after the main motor stops.
  • Page 81 4.10.1 Replacement and Adjustment 1. Cleaning Unit Removal Drum Stay 1. Remove the development unit. 2. Lower the T/S corona unit. Knob 3. Remove the charge corona unit (1 screw) and the drum stay (1 knob and 1 screw). NOTE: The drum stay knob has a reverse thread.
  • Page 82 3. Cleaning Brush Replacement Cleaning Unit 1. Remove the cleaning unit drive gear (1 Drive Gear Allen screw), the collar, and the bushing Collar Bushing Entrance Seal from the rear end of the cleaning brush shaft. 2. Remove the bushing from the front end (1 E-ring).
  • Page 83 11. Assemble the pawl shaft assembly and place it into the cleaning unit, sliding the rear end of shaft into the hole in the rear Pawl Shaft Pin side plate. Spring End NOTE: 1. When installing the cam holder and the cam rider, align [A] with [B] as shown in the figure.

  • Page 84: Fusing

    4.11 FUSING 4.11.1 Overview Hot Roller Fusing Lamp Hot Roller Stripper Fusing Exit Rollers Fusing Thermistor Pressure Roller Pressure Spring Pressure Lever The image is fused to the copy paper by two rollers which apply heat and pressure. The hot roller is made of teflon and the pressure roller is made of silicone rubber. Pressure is constantly applied between the rollers.
  • Page 85 4.11.2 Mechanical Parts 1. Fusing Drive Release Gear The fusing drive gear turns the release gear which drives the hot roller gear. Hot Roller Gear Rotation passes from the hot roller gear through two idle gears to the exit rollers. The pressure roller is driven by the friction between the two fusing rollers.
  • Page 86 2. Fusing Temperature Control This machine controls the fusing temperature based on a zero cross signal. After the main switch is turned on, the fusing lamp remains lit until the temperature reaches 165°C. Then fusing lamp control shifts to ON/OFF control until the fusing temperature reaches the operating temperature (185°C).
  • Page 87 4.11.3 Replacement and Adjustment 1. Fusing Unit Removal 1. Open the front cover. Stopper Pin 2. Push the fusing unit release lever to the right. 3. Pull out the fusing unit until it is fully extended. 4. Push the fusing unit release lever to the right, move the fusing unit to the left to disengage the stopper pin, and remove the unit from the copier.
  • Page 88 Hot Roller Gear Fusing Exit Ass’y Bearing Pressure Spring Hot Roller Harness Support Collar Bracket Rear Lamp Terminal CAUTION: After installing the fusing lamp, check that the lamp does not contact the inside of the roller by rotating the fusing lamp insulator. Make sure that both front and rear fusing lamp insulators are properly set in the terminal sockets.
  • Page 89 4. Hot Roller Stripper Replacement 1. Pull out the fusing unit and open the fusing exit assembly. 2. Unhook the springs and remove the hot roller strippers. 3. Install new strippers and connect the springs. Hot Roller Stripper Spring 5. Thermofuse Replacement Thermistor 1.

  • Page 90: Misfeed Check

    4.12 MISFEED CHECK 4.12.1 Overview The CPU uses the registration sensor and the fusing exit sensor to check for paper misfeeds. When there is a paper misfeed, the check paper path ( ) indicator lights or blinks and the copier stops. Check the misfeed location display. Location A: Feeding Section Location B: Fusing Unit Location D: Sorter...

  • Page 91: Pulse Generator

    4.13 PULSE GENERATOR Pulse Generator 4.13.1 Overview Pulse Generator Disk Sensor The CPU uses a pulse generator to check the drum clock during a copy cycle. When the Start key is pressed, the main motor turns on and the clock signal is generated by the revolution of the disk assembly.

  • Page 92: Others

    4.14 OTHERS 4.14.1 Operation Panel Removal Operation Panel Side Panel Bracket DC Harness Inner Panel Brackets 1. Turn off the main switch and open the front covers. 2. Remove the 2 screws securing the operation panel to the inner panel brackets. 3.

  • Page 93: Sp Mode/Dip Sw Table

    5. SP MODE/DIP SW TABLES 5.1 SERVICE PROGRAM MODE......93 5.2 DIP SWITCH TABLES........96 5.3 INPUT CHECK MODE........97 - 92 -...
  • Page 94 5.1 SERVICE PROGRAM MODE 1. Service Program Access Procedure For service For sales representatives and Function Remarks representatives customers Access SP TURN ON "00" WILL BE mode DPS101-2 ON DISPLAYED IN THE THE MAIN MAG. RATIO BOARD. INDICATOR. CLEAR STOP ENERGY SAVER /CLEAR MODES "0"...
  • Page 95 2. Service Program Mode Table Mode Defaults Data All Indicators On 10: OFF 11: All the indicators on the Operation (NOTE 2) Panel turn on. Misfeed Detection Off 10: OFF 11: Copies are made without misfeed detection. Exposure Lamp Off 10: OFF 11: The exposure lamp is off in Free Run mode.
  • Page 96 Mode Defaults Data Forced Start 10: Normal (NOTE 3) 11: The ready temperature is ignored to turn the Start key green. (Factory use only) Input Check 10: Normal (NOTE 5) 11: Input data from the sensors is displayed. Refer to section 5-3. Key Card Operation 10: Not used 11: The Key Card operates.
  • Page 97 5.2 DIP SWITCH TABLE 1. Main Board 1) DPS 101 TONER MODE DENSITY 3.5% NORMAL FREE C MODE MODE 10.5% HIGH NOR- NOR- P MODE HIGHER 2) DPS 102 LARGE LARGE SCANNER ↑ ↑ FREE RUN PRODUCTION NORMALLY ON ↓ ↓...
  • Page 98 5.3 INPUT CHECK MODE When you enter the SP mode 88, the copier displays the sensor readings on the monitor. NOTE: Before checking the sensor data with this input check mode, you have to leave the SP mode. MODE REMARKS "= "...

  • Page 99: Call Service Conditions

    6. CALL SERVICE CONDITIONS 6.1 CALL SERVICE CONDITION CODES....91 6.2 CALL SERVICE CONDITION DETAILS .... 92 - 98 -...
  • Page 100 6.1 CALL SERVICE CONDITIONS Unit Code Definition Detail Exposure lamp malfunction Displayed if the lamp filament is broken or if the lamp turns on during stand-by. Exposure Lamp relay malfunction Displayed if the lamp stays off or the lamp stays on longer than 10±4 seconds during a copy cycle.
  • Page 101 Unit Code Definition Detail Total counter malfunction Displayed if the total counter is not set or is defective. Communication error between the optics The main board is defective. CPU and the main CPU. Communication error between the The operation panel board or main board is defective. Poor connection Others operation panel board and the main board.
  • Page 102 PROBLEM CAUSE ACTION STATUS "21" 1. SCANNER DRIVE MALFUNCTION 1. Check that the scanner is working properly. → If it is, check CN403-4 on the main board. (SCANNER HOME 1) SCANNER MOTOR PULLEY SCREW 5V → Replace the main board. POSITION NOT ON) UNLOCK 0V →...
  • Page 103 PROBLEM CAUSE ACTION STATUS "2A" 1. 2ND SCANNER HOME POSITION 1. Check if the 2nd scanner is moving properly. (2ND SCANNER HOME DETECTION MALFUNCTION Moving properly POSITION NOT ON) 2. 2ND SCANNER DRIVE SECTION Check CN403-6 on the main board. :When 2nd Scanner Motor is OFF →...
  • Page 104 PROBLEM CAUSE ACTION STATUS "54" 1. POWER RELAY POOR CONTACT START (READY SIGNAL NOT ON) 2. FUSING LAMP OPEN 3. FUSING CONTROL BOARD MALFUNCTION FUSING REPLACE THE IS FUSING CONTROL LAMP FUSING CONTROL BOARD CN1-8 (LOW) 4. MAIN BOARD MALFUNCTION BOARD 5.
  • Page 105 PROBLEM CAUSE ACTION STATUS "61" 1. PULSE GENERATOR MALFUNCTION 1. Check whether the pulse generator disk is rotating. (PULSE GENERATOR 2. POWER RELAY MALFUNCTION Rotating MALFUNCTION) 3. MAIN BOARD MALFUNCTION Check the output of the pulse generator at CN102-A5 on the main board. 4.

  • Page 106: Preventive Maintenance

    7. PREVENTIVE MAINTENANCE 7.1 OVERVIEW............98 7.2 PM TABLE............99 7.3 EXPLANATION OF REGULAR PM ....101 7.4 REGULAR PM PROCEDURE ......103 - 105 -...

  • Page 107: Overview

    7.1 OVERVIEW The Purpose of PM (Preventive Maintenance) 1) Regular exchange of worn out parts 2) Removal of dirt to maintain good copy quality 3) Inspection and adjustment to maintain good copy quality 4) Lubrication 5) Replacement of defective parts 6) At service call, deal with customer’s complaints with advice and instruction.

  • Page 108: Pm Table

    7.2 PM TABLE O: Clean : Replace : Lubricate : Inspect Regular Item Mainte- Note Check nance Optics Mirrors, Lens, Reflectors Silicone cloth or cotton pad with water, blower brush Exposure glass Alcohol or water Platen cover sheet Alcohol or water Scanner guide rod, guide rail, After lubicating with launa guide rod felt...
  • Page 109 Regular Item Mainte- Note Check nance Development unit Developer After replacement, condition the drum for 99 cycles Side seals Replace if necessary Development unit gears Water or dry cloth Toner tank Clean if necessary Entrance seal Dry cloth Fusing unit Hot roller Do not scratch Pressure roller...

  • Page 110: Explanation Of Regular Pm

    7.3 EXPLANATION OF REGULAR PM Item Explanation Optics unit Mirror, Lens, Reflector, Stains on any part of the optics unit result in a dirty Exposure Glass, Platen background, black lines, black spots, or areas of Cover, Toner Shield Glass decreased sharpness on the copy image. Periodic cleaning is required.
  • Page 111 Item Explanation Fusing Unit Hot Roller A worn out hot roller and pressure roller will cause fusing malfunction, and dirty copies. Replace at regular Pressure Roller intervals. Thermistor If toner accumulates on the thermistor, fusing temperature control may not be accurate. Inspect the thermistor at regular intervals.

  • Page 112: Regular Pm Procedure

    7.4 REGULAR PM PROCEDURE Make a copy Make 11 copies of your test chart (OS-A3) at manual image density level 2, and use the 11th copy. Optics (every 40K) 1. Clean the mirrors, lens and reflectors with a silicone cloth, cotton pad with water, or a blower brush. 2.
  • Page 113 Development unit 1. Clean the development unit guide plate in the copier (every 40K) with a damp cloth. 2. Remove the old developer. 3. Clean the entrance seal and upper brush seal. 4. Inspect the side seals and the toner supply section. 5.
  • Page 114 Machine front side Lubricate the oilless bushings using spindle oil. (every 80K) Exterior unit Clean the covers. Copy quality After performing drum conditioning for 10 copies, turn off the DIP SW on the operation panel board and make a copy within 10 seconds. - 113 -...

  • Page 115: Troubleshooting

    8. TROUBLESHOOTING - 114 -...
  • Page 116 1. White Copy Problem Cause White copy 1. Charge is not applied. Due to C-B power pack failure, poor contact of the H-V lead wire, or a broken wire, charge is not applied on the drum surface. 2. The copy image is not transferred to the paper. Due to transfer /separation P.P.
  • Page 117 Action Remarks White Copy H L H:5V OFF ON L: less than 0.5V 1. Check the charge corona wire 2. Check CN101-A17 on the main board goes from 5 to 0V 3. Check between conn. #1 ~ #14 on the BCP Power Pack BC power pack 4.
  • Page 118 2. Dirty Background Problem Cause When copying, dirty 1. The charge corona wire is dirty background will appear If the charge corona wire is contaminated, the charge on the drum at manual image surface is increased due to a thicker diameter of the wire. density level 4.
  • Page 119 Action Remarks After attaching the pad soaked with launa oil, Dirty Background don’t attach the exposure glass. Then perform 10 copies in free run mode. Lamp regulator Charge Corona output adjustment 1. Clean the charge corona wire 2. Check the mounting position of the wire 1.
  • Page 120 Action Remarks Doctor Gap is too wide 1. Check the doctor gap Deterioration of Drum 1. Adjust the lamp regulator Voltage 2. Replace the drum After adjusting the lamp voltage, adjust V =3.0±0.06V Deterioration of Developer 1. Replace the developer VDE high? Adjust VDE - 119 -...
  • Page 121 3. Uneven Image Density Problem Cause Uneven image density 1. Uneven charge current. appears on solid black (1) Contamination of the charge corona unit. copies. (2) Uneven mounting height of the charge corona wire. The copied pattern will not change regardless of reproduction ratio.
  • Page 122 Action Remarks Uneven Image Density Charge Corona 1. Clean the charge corona wire 2. Check the wire height Mirrors and Exposure Glass 1. Clean the mirror, lens and exposure glass Exposure Lamp 1. Check for exposure lamp deterioration 2. Adjust the exposure lamp positon - 121 -...
  • Page 123 4. Vertical Black Line Problem Cause Black stripe on the rear When pulling out the development unit, the toner shield glass is moved out side of the copy. of position due to contact with the development unit. Black line Vertical black line on 1.
  • Page 124 Action Remarks * Due to adhering launa oil, the 1st and 2nd mirrors may be Vertical Black Line contaminated. * Due to deterioration of the exposure lamp, a black line may appear Development on the copy. Unit If the filament is stretched, see below.
  • Page 125 5. Vertical White Lines Problem Cause Indistinct white line on Due to contamination of the charge corona wire, or corona unit casing the rear side of the roughness. copy. Indistinct white line A scraped white line will Toner on the drum is scraped off by an unknown foreign substance. appear on the copy.
  • Page 126 Action Remarks Vertical White Lines *Due to deterioration of the charge corona wire, sharp white lines will Charge Corona appear on the copy. Check the charge corona wire Cleaning Blade Check the cleaning blade Foreign Substance ID Sensor Toner Pile-up T/S Guide Plate - 125 -...
  • Page 127 6. Horizontal Black Line Problem Cause Black lines 1. The drum is scratched. perpendicular to 2. The hot roller is scratched. the paper feed 3. Toner adheres to the drum surface as a result of blade pressure. direction appear Note: Check the interval of the appearance of horizontal black lines. on the copy If black lines appear at 251 mm intervals, the cause is a scratched drum or image.
  • Page 128 Action Remarks Horizontal Black Line Drum Check the Drum Hot Roller Check the Hot Roller Cleaning Blade Check the Cleaning Blade Seals on dev. unit Check the seals on the dev. unit Check the erase lamp Drum Check for scratches on the drum No scratch on the drum Clean the drum surface...
  • Page 129 7. Jitter Problem Cause The cause is the scanner drive pulley (24 ∅) Jitter appears at 80 mm intervals on the copy. 1. Irregular revolution of the scanner drive motor. 2. The pulley has burrs or scratches on the surface. Irregular jitter appears It may be caused by an incorrect voltage being supplied from the power on the copy.
  • Page 130 Action Remarks Jitter Scanner Drive Motor 1-1. Check the scanner drive motor Scanner Drive Pulley 1-2. Check the scanner drive pulley Power Supply Unit Check the scanner movement Check the optics control board Check the scanner drive motor Check the power supply unit Action Remarks 1.
  • Page 131 9. Distorted Copy Image Problem Cause The copied image is a The 1st scanner and 2nd scanner are not parallel. parallelogram shape * This problem may occur if the scanner lock plate is not mounted when transporting the copier. Original Front side of 2nd scanner Copy (2) Copy (1)
  • Page 132 10. Image Density is too high Problem Cause The toner density is too 1. The lamp regulator output voltage is too high. high 1. Dirty background 2. The bias voltage is too high. may appear on the 3. The charge current is too low. copy.
  • Page 133 Action Remarks Toner Density too High 30% in Detect Supply Mode Mark the toner supply shaft Set SP mode (30) to "10" Make the following DIP SW Press the Start key after settings: 101-3: "ON" the main switch is turned OFF 101-4: "OFF"...
  • Page 134 Action Remarks To decrease toner density, set DIP SW 101-3 "OFF" and 101-4: "ON" Make 10-20 copies in A3 size with the platen cover Clean the ID sensor open with a blower brush or Clean inside copier, especially the PTL and ID dry cloth sensor >...
  • Page 135 11. Toner Density is too low Problem Cause The toner density is too 1. V is out of adjustment low. When V is lower than 2.5 V, the toner supply shifts to fixed supply mode. 1. Density of solid 2. The charge current is too high areas is too low.
  • Page 136 Action Remarks Image Density too Low Detect Supply Mode 30%? Mark on the toner supply Clutch Shaft. Set SP mode (30) to "10". Turn on DIP SW 101-2 on the Make the following DIP SW main board settings. 101-3: "ON", 101-4: "OFF" Press the Start key 2.6 revolutions per copy...
  • Page 137 Action Remarks > 2.5V Make 20 copies with the drum Check the ID sensor conditioning switch ON and mounting check the revolution Is the Toner Supply Shaft revolving? VSP > 0.5V Check the main control board Check the charge current and bias voltage Is V displayed in the size...
  • Page 138 12. Copy Image is insufficiently fused Problem Cause The image can be 1. The nip width is too narrow. rubbed off with fingers. 2. The fusing temperature is too low. 3. Thermistor malfunction. Action Remarks 1. Replace the pressure spring on the fusing unit. Specification 5.6 ±...
  • Page 139 13. Scanner movement is out of control Problem Cause When the main power 1. When the power becomes too low (less than 160V) the reset signal switch is turned on, the cannot be transmitted to the optics control board. This causes the scanner is driven to the scanner to be driven to the return position.

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