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Ricoh FT3320 Field Service Manual
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Ricoh FT3320 Field Service Manual

Ricoh FT3320 Field Service Manual

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FT3320
F I E L D
S E R V I C E
M A N U A L
ICOH COMPANY, LTD.

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Summary of Contents for Ricoh FT3320

  • Page 1 FT3320 F I E L D S E R V I C E M A N U A L ICOH COMPANY, LTD.
  • Page 2 Table of Contents INSTALLATION SERVICE TABLES REPLACEMENT AND ADJUSTMENT...
  • Page 5 VINYL ENVELOPE POINT-TO-POINT ELECTRICAL COMPONENT AND CONNECTOR LAYOUTS TABLE OF ADJUSTMENTS SERVICE TABLES...
  • Page 6 SECTION 1 INSTALLATION...
  • Page 7 INSTALLATION 5-1 SHORT HAUL TRANSPORTATION ......1-14 5-2 LONG HAUL TRANSPORTATION BY VEHICLE ..1-14...

  • Page 8: Installation Requirements

    1 NOV. ’87 1. INSTALLATION REQUIREMENTS 1-1 ENVIRONMENT 10*C to 30°C (50°F to 86°F) 1. Temperature Range: 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 Iux (Do not expose to direct sunlight.) 4. Ventilation: Room air should turn over at least 3 times/hour. 5.
  • Page 9 1 Nov. ’87 1-2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2”) of level. 2. Right to left: Within 5 mm (0.2”) of level. Set a carpenter’s level on the exposure glass to check the machine level. 1-3 MINIMUM SPACE REQUIREMENTS 1.
  • Page 10 1 Nov. ’87 POWER REQUIREMENTS 1. Input voltage level: • 110V/60Hz More than 12A ž115V/60Hz : More than 12A • 220V/50Hz : More than 6A 2. Permissible voltage fluctuation: 10%. At least 300V, 30A capacity and less than 5 3. Permissible extension meters long.
  • Page 11 1 Nov. ’87 1-5 ACCESSORY CHECK Check the accessories and their quantities according to the following list: 1 pc Cassette 1 pc Copy Tray Drum 1 pc Operating Instructions NECR 1 pc Envelope for NECR (1 15V only) 1 pc Multi-lingual Decal (220/240V only) 1 pc.

  • Page 12: Copier Installation

    N o v . ' 8 7 2. COPIER INSTALLATION 1. Remove the 6 strips of shipping tape [A]. 2. Remove the lock plate cover [B] from the left cover [C] (1 screw). 3. Remove the scanner lock plate [D] (1 screw). Re-install the lock plate cover.
  • Page 13 1 NOV. ’87 When the transport lock plate is removed, the transport unit may fall NOTE: and be damaged; to prevent this, gently lower the transport unit using the transport release lever [B]. Remove the development retainer plate [C] from the drum stay [D] (1 screw).
  • Page 14 8. Remove the charge corona unit [A] together with the wire cleaner [B] ( 1 screw). 9. Place a sheet of paper [C] over the T/S corona unit [D]. 10. Remove the drum stay [E] (1 screw and 1 knob). The drum stay knob is reverse threaded.
  • Page 15 1 Nov. ’87 Remove the oil supply pad [A]. Prime the oil supply pad with silicone oil [B]. Re-instaH the oil supply pad. 16 . NOTE: Two notches of the oil supply pad must rest on the two hooks, The tail of the oil supply pad must be in the oil sump.
  • Page 16 1 Nov. ’87 Separate the toner tank [A] from the development unit [B] (2 screws). 21 . 22 . Pour one pack of developer (Developer Type 3300) [C] into the develop- ment unit while turning the knob [D] counterclockwise to distribute the developer.
  • Page 17 1 Nov. ’87 the cleaning unit, keep it away from the drum sur- NOTE: When inserting face. + with the wire and the charge corona unit complete 28. Set the drum stay cleaner. the transport over the T/S corona unit and return 29.
  • Page 18 1 Nov. ’87 Remove the toner hopper seaI [A], then install one toner cartridge [B]. NOTE: Refer to the decal on the machine or the Operating Instructions for the toner supply procedure. 32 . For 240-volt areas, remove the rear cover (2 screws) and reposition the 220/240 -voIt connector on the ac drive board.
  • Page 19 1 Nov. ’87 3. KEY COUNTER HOLDER INSTALLATION Remove the rear and right covers. Cut out the key counter access hole section [A] with nippers [B]. Remove the shorting plug [C] from the key counter connector (4p). Connect the connector [D] (4p) of the key counter holder to the key counter harness through the access hole [E].
  • Page 20 1 Nov. ’87 4. CASSETTE MODIFICATION Remove the cassette cover [A]. 2. Remove the arm pins (1 “E” ring each) and lift out the side fence arms [B] . . for future use. NOTE: Keep these parts 3. Remove the bottom plate [C]. 4.

  • Page 21: Transporting The Copier

    1 Nov. ’87 5. TRANSPORTING THE COPIER Always hold the copier at the correct places (see illustration). The copier may be seriously damaged if it is moved without the following preparation: 5-1 SHORT HAUL TRANSPORTATION Remove the copy tray and the cassette. 2.
  • Page 22 1 Nov. ’87 5-2 LONG HAUL TRANSPORTATION BY VEHICLE 1. Remove the developer (see Developer Replacement). 2. Install the transport lock plate [A] (1 screw). 3. Temporarily remove the lock plate cover [B] (1 screw) and fit the scan- ner lock plate [C] (1 screw), and re-install the lock plate cover. procedure position before this The scanner should be in the home...
  • Page 23 SECTION 2 SERVICE TABLES...
  • Page 24 SERVICE TABLES...
  • Page 25 1 Nov. ’87 1. PM TABLE R: Replace A: Adjust C: Clean 1: Inspect L: Lubricate 120K 160K NOTES ITEM OPTICS Water (replace if Platen cover necessary) sheet Water or alcohol 2. Exposure glass Silicone cloth or Lens, mirrors, blower brush reflector, toner shield glass...
  • Page 26 1 Nov. ’87 R: Replace A: Adjust C: Clean I: Inspect L: Lubricate NOTES 120K 160K ITEM PAPER FEED Cloth (water), Pickup roller replace if necessary Cloth (water) 2. Registration rollers Cloth (water) 3. Cassette Bot- tom Plate Pad Cloth (water) 4.
  • Page 27 1 Nov. ’87 R: Replace A: Adjust C: Clean I: Inspect L: Lubricate NOTES 120K 160K ITEM Oil Blade DEVELOPMENT If necessary Developer Clean off paper dust 2. Toner scatter- and other dirt ing prevention seal 3. Side seals Clean with soft cloth Development when replacing unit guide...
  • Page 28 1 Nov. ’87 2. GENERAL SERVICE TABLES Test Points Function Number TPI02 Original ID sensor voltage TPI03 TPI04 image density sensor voltage 2 2 - Variable Resistors Number Function VR101 Adjusts the original sensor voltage Adjusts the image density sensor voltage VR102...
  • Page 29 1 N o v . ’ 8 7 2-3 DIP Switches Function DIP Switch Normal Lead edge registration adjustment 1 101-1 Lead edge registration adjustment 2 101-2 Lead edge registration adjustment 3 101-3 Lead edge registration adjustment 101-4 Test Mode 101-5 Free Run.
  • Page 30 1 Nov. ’87 ID Sensor Bias DPS102-2 ID Bias DPSI02-I 420 V 470 V 520 V 550 V...

  • Page 31: Test Mode

    1 Nov. ’87 3 TEST MODE 3-1 Output Mode: This mode is used to make various adjustments and to check the operations of electrical devices. Press the Start key to emergize the mode, and press the C/S key to de-emergize. Operation Enterred No.
  • Page 32 conditions’. Be careful not to leave the lamp on for a long time. When the exposure lamp is turned on, after 20 seconds, auto- shut off occurs. original ID sensor data (Hex code) is displayed in the opera- tion panel (see 9-2 Original ID Sensor Adjustment). #3 If the scanner is in the position during this operation, (H.
  • Page 33 1 Nov. ’87 Input mode: of sensors and This mode is when checking the ON / OFF operation used the Start key to switches. The data is displayed in the operation panel. Press emergize the mode, and press the C/S key to de-emergize. Data 2 Function Enterred No.

  • Page 34: Serviceman Mode

    1 Nov. ’87 4. SERVICEMAN MODE There are six serviceman modes, which have the following functions: FUNCTION NAME This is to confirm if the toner end Toner End “C/S”, “0” and Back Up "3" back up mode functions or not.*2 Mode In this mode, a copy of the ID ID Sensor...

  • Page 35: Service Remarks

    1 Nov. ’87 5. SERVICE REMARKS General Cautions Keep hands away from mechanical drive components when the copier is warming This is to avoid possible injury when the copier starts idling at the end of warm up. (The warm-up idle cycle occurs when DPS102-4 is ON.) The copier also idles after warm up to lift the copy paper to the feed position if paper is not in the correct feeding position.
  • Page 36 “87 Nov. 3. Clean the exposure glass with water or glass cleaner. Clean the mirrors with alcohol and/or water and a soft cloth only. 5. Do not touch the following parts with your bare hands: Reflectors Exposure lamp Mirrors and lens 6.
  • Page 37 1 Nov. ’87 Transfer and Separation 1. The corona wires should be cleaned with a dry cloth at every EM or PM. 2. While the drum stay is removed and the drum is installed on the drum guide, do not lift up the transport unit. (The corona casing will knock against the drum and damage it.) Cleaning When servicing, be careful not to damage the edge of the cleaning blade.
  • Page 38 1 Nov. ’87 Handling the Drum Never touch the drum surface with your bare hands. Store the drum in a cool dry place away from heat. When cleaning the drum, always use a pair of gloves. Do not throw away cotton used for cleaning. Bring it back to the service depot for dis- posal according to local regulations.

  • Page 39: Special Tools And Lubricants

    1 Nov. ’87 6. SPECIAL TOOLS AND LUBRICANTS Remarks Description Part Number 2 pcs/sa DG Gauge AO179505 10 sheets/set Test Chart OS-A4 52149500 100 sheets/set Test Chart OS-A4 52149501 Setting Powder 54429101 Drum Shoe 54429106 Shoe Adapter 54479104 Digital Thermometer 54209504 Digital Thermometer 54209505...
  • Page 40 SECTION 3 REPLACEMENT AND ADJUSTMENT...
  • Page 41 REPLACEMENT AND ADJUSTMENT...
  • Page 43 ‘ 1. OPTICS EXPOSURE GLASS REMOVAL Take off the left scale [A] (2 screws). Slightly lift up the left edge and slide out the exposure glass [B]. NOTE: a) Place the exposure glass on a sheet of paper in order not to scratch the surface.
  • Page 44 1 Nov. ’87 SECOND MIRROR REMOVAL ” Turn off the main switch. Exposure Glass Removal). Remove the exposure glass (see 1-1 Way to the right, by pushing it at the Move the 1st scanner [A] 2/3 of the rear. Remove the rear spring pIate [B] by pressing the top and bottom of the plate and moving the plate towards the back of the machine.
  • Page 45 1-3 EXPOSURE LAMP REPLACEMENT Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as finger oil. marks will b e c o m e discolored due to the heat. 1. Turn off the main switch. 2.
  • Page 46 1 NOV. ’87 8. Fit the lamp stopper [H] to the rear terminal of the new exposure lamp, and install the lamp. NOTE: Make sure the stopper fits in the terminal hole [1]. Reassemble the 1st scanner. Check the exposure lamp position is correct (see 1-4 Exposure Lamp Position Adjustment).
  • Page 47 1 Nov. ’87 1-4 EXPOSURE LAMP POSITION ADJUSTMENT 1. Turn off the main switch. 2. Remove the exposure glass (see 1-1 Exposure Glass Removal). 3. Move in the central the 1st scanner so that the exposure lamp is located area of the mylar. 4.
  • Page 48 1 Nov. ’87 - Vertical Adjustment - 7. View the exposure lamp filament [A] through the right ventilation holes [B] in the upper cover. The filament should be level with the sight holes. 8. To correct the position of the filament, turn the front and rear adjusting knobs [C].
  • Page 49 1 Nov. ’87 1-5 SCANNER DRIVE WIRE REPLACEMENT 1. Turn off the main switch and unplug the copier. 2. Remove the platen cover, and upper cover (6 screws). 3. Remove the rear cover (2 screws). 4. Open the front cover and remove the following covers: a) lock plate cover (1 screw) b) left cover (4 screws)
  • Page 50 1 NOV. ’87 Hook the bead [A] of the new wire in the anchorage point on the rear plate [B], and run it over the pulleys in the following order: a) inner track of WP1 b) via the wire clamp [D] to WP2 c) inner to outer on WP3 (3 times) to WP4 d) outer track of WPI to WT.
  • Page 51 ’ 8 7 N o v . REVERSE CLUTCH DAMPER REPLACEMENT 1. Turn’ off the main switch, unplug the copier, remove the rear cover (2 screws), upper cover (6 screws) and the right cover screws). 2. Remove the main PCB screws, 19 connectors, 1 locking support, 3 wire clamps).
  • Page 52 1 Nov. '87 2. DEVELOPMENT 2-1 DEVELOPER REPLACEMENT Take care not to damage the upper brush seal. After removing used developer, clean the drive gears. Open the front cover, loosen the development retainer plate (1 screw), raise the development lock lever and pull out the development unit. Separate the toner tank [A] from the development unit [B] (2 screws).
  • Page 53 1 Nov. ’87 To remove the trapped developer at the ends of the development unit, hold up the unit at an angle, and alternatively turn the knob and gently shake the unit. Repeat steps 5. and 6. until all the developer is removed. Place the development unit on a level surface and pour in one pack of FT3300 developer [E] (750 g) while turning the paddle roller knob [F].
  • Page 54 1 NOV. ’87 2-2 DEVELOPMENT SET SENSOR REPLACEMENT 1. Turn off the main switch and unplug the copier. Replacement). 2. Remove the development unit (see 2-1 Developer 3. Remove the main PCB (see 1-6 Reverse Clutch Damper Replacement), -- Remove the 1 screw, 2 locking supports, and CNI on the CTB power pack [A], and swing it to the right.
  • Page 55 1 NOV. ’87 2-3 TONER SUPPLY CLUTCH REPLACEMENT 1. Remove the main PCB (see 1-6 Reverse Clutch Damper Replacement). 2. Remove the toner supply clutch assembly [A] (3 screws), and separate the clutch [B] from the bracket by removing the clutch-shaft [C] (1 “E” ring).
  • Page 56 1 Nov. ’87 2-4 IMAGE DENSITY SENSOR CHECK AND ADJUSTMENT NOTE: The ID sensor adjustment is required in the following situations: a) When the Main PCB is replaced. b) When the drum has been replaced and Vsg is out at standard. c) When a problem with toner supply occurs, and checking the ID sensor voltage shows the Vsg is out of standard.
  • Page 57 3. Turn off the main switch and turn on DPS 101-6 (Free Run) on the main PCB. 4. Turn on the main switch while pressing the “C/S”, “O”, and “8” keys at the same time. 5. When the copier is ready, press the “Start” key in order to show the Vsg voltage in the operation panel.
  • Page 58 1 Nov. ’87 METHOD B: Reading from a Digital Multimeter 1. Clean the image density sensor. 2. Turn off the main switch and turn on DPS 101-5 (Test Mode) on main PCB. 3. Hook up the digital multimeter leads as follows: a) positive lead to TP104 b) negative lead to TP103 (GND).
  • Page 59 1 Nov. ’87 7. If Vsg is incorrect, adjust VR102 on the main PCB in order to obtain 4 ± volts. 8. Press the “C/S” key to stop the copier, turn off the main switch and turn off DPS 101-5. 3-17...
  • Page 60 1 Nov. 2-5 DOCTOR GAP ADJUSTMENT ADJUSTMENT STANDARD: 0.72 mm (0.028”) NOTE: This adjustment is done only when the doctor blade has been removed or replaced. 1. Remove the upper brush seal cover [A] (2 screws). 2. With the development roller facing upwards, turn the roller sleeve in the opposite direction to normal operation by using the development roller gear [B], until the roller is free from developer.
  • Page 61 1 Nov. ’87 2-6 IMAGE DENSITY SENSOR AND DRUM Thermistor REPLACEMENT 1. Turn off the main switch and unplug the copier. 2. Remove the rear cover (2 screws). 3. Disconnect CNI 08 (3p) on the main PCB, and CN2 (2p) on the power pack.
  • Page 62 1 Nov. ’87 6. Replace the sensor assembly. NOTE: a) When installing the assembly, first feed the two harnesses through the hole [B] and towards the rear of the machine. Then the sensor facing downwards [C], insert the assembly with in the hole and rotate to the left (1 and 2).
  • Page 63 1 Nov. ’87 3. CLEANING 3-1 USED TONER DISPOSAL Remove the cleaning unit, place it on a sheet of paper and turn the clean- ing brush in the cleaning direction, in order to feed the remaining toner in the cleaning unit into the used toner tank. Remove the used toner tank upper cover [A] (5 screws).
  • Page 64 1 NOV. ’87 3-2 CLEANING BLADE REPLACEMENT 1. Remove the cleaning unit [A], and remove the cleaning blade [B] (1 shoulder screw). 2. Replace the cleaning blade being careful not to touch the edge of the blade. After installing the blade, make sure it swivels from side to side. 3-22...
  • Page 65 1 N o v . ’ 8 7 3-3 CLEANING BRUSH REPLACEMENT 1. Remove the cleaning unit and remove the cleaning brush gear [A] (1 “E” ring). 2. Remove the cleaning brush idle gear [B] (1 screw), and the front and rear bushings [C] from the cleaning brush shaft (1 “E”...
  • Page 66 1 Nov. ’87 3-4 PICK-OFF PAWL REPLACEMENT 1. Remove the cleaning unit and remove the 2 pick-off pawls [A] (1 snap ring each). pick-off pawls, making sure the pick-off bars [B] are fitted 2. Replace the correctly in between the pick-off pawls’ tails. NOTE: When replacing the pick-off pawls, it is advisable to replace both of the pawls at the same time.
  • Page 67 CLEANING PRESSURE ADJUSTMENT ADJUSTMENT STANDARD :44 mm Take care when doing this procedure as the power is on. NOTE: When doing this procedure, make sure that the cleaning unit and the drum are fitted in the machine. 1. Turn off the main switch. 2.
  • Page 68 4. QUENCHING PRE-TRANSFER LAMP REPLACEMENT 1. Turn off the main switch and unplug the copier. 2. Remove the following parts: a) development unit b) charge corona unit c) drum stay d) cleaning unit e) drum flange f) drum g) main PCB. 3.
  • Page 69 1 N O V . ’ 8 7 To ease the fitting or removing of the clutch, move the main motor NOTE: assembly towards the right. 5. Remove the PTL [F] (1 screw, 1 connector) by pulling it out diagonally, thus not hitting the main motor.
  • Page 70 1 NOV. ’87 4-2 QUENCHING LAMP REPLACEMENT 1. Turn off the main switch and unplug the copier. 2. Remove the following parts: a) development unit b) charge corona unit c) drum stay d) cleaning unit e) drum flange f) drum. 3.

  • Page 71: Paper Feed

    ’ 8 7 1 Nov. 5. PAPER FEED PICK-UP AND FEED ROLLER REPLACEMENT Open the manual feed table [A], and remove the front and rear manual feed links [B] (1 “E” ring each). Remove the manual feed table (1 “E” ring, 1 stud screw). Remove the right plate holder [D] (1 screw), and remove the manual feed pIate [E].
  • Page 72 1 Nov. ’87 5-2 REVERSE ROLLER REPLACEMENT roller [B] (1 Remove the reverse roller cover [A] (2 screws), the reverse snap ring), and the slip clutch assembly. Disassemble the slip clutch assembly, clean and lubricate the spring with Mobil Temp 78. Reassemble the clutch assembly, making sure that the pin fits correctly into the cut-out part of the assembly.
  • Page 73 1. Turn off the main switch and unplug the copier. 2. Remove the rear cover (2 screws) and the right cover (4 screws). 3. Remove the CTB power pack [A] (1 screw, 2 locking supports, 2 connec- tors, 3 terminals). 4.
  • Page 74 1 Nov. ’87 feed clutch disassemble the 6. Remove paper [F] (1 “E” ring), and clutch (see illustration). 7. Clean and lubricate the clutch spring with Mobil Temp. 78, then assemble the clutch, making sure that the spring [H] is fitted correctly (see illustration).
  • Page 75 5-4 PAPER LIFT CLUTCH REPLACEMENT Turn off the main switch and unplug the copier. Remove the rear cover (2 screws), and the right cover (4 screws). Remove the power pack (1 screw, 2 locking supports, 2 connectors, 3 terminals), and remove the sector gear (1 screw) [A]. Remove the paper feed clutch bracket (2 screws, 1 wire clamp).
  • Page 76 1 Nov. ’87 gear [E] when removing the as- b) Take care not to drop the idle sembly. 7. Fit the lift release spring [F] to the new paper feed clutch assembly and install the assembly. NOTE: a) When installing the assembly, make sure that the lift clutch shaft is in the correct position (see illustration) and take note that it has a “D”...
  • Page 77 1 Nov. ’87 5-5 REGISTRATION SENSOR REPLACEMENT Turn off the main switch. Open the front cover and remove the development unit. Remove the right inner cover [A] (4 screws). Uncouple the registration sensor connector [B] and snap-out the male connector [C] from the front plate (see illustration). Lower the transport unit and remove the T/S corona unit.
  • Page 78 1 Nov. ’87 5-6 PAPER END AND PAPER LIFT SENSOR REPLACEMENT 1. Turn off the main switch. feed table and slide the paper guides [A] to their 2. Open the manual widest position. entrance guide [B] (2 screws). 3. Remove the upper - Paper End Sensor - end sensor assembly [C] (1 screw, 1 connector).
  • Page 79 1 Nov. ’87 5-7 MANUAL FEED SENSOR REPLACEMENT 1. Turn off the main switch. 2. Remove the front and rear manual feed links [A] (1 “E” ring each), and then remove the manual feed table [B] (1 “E” ring, 1 stud screw). 3.
  • Page 80 1 Nov. ’87 6. TRANSPORT AND FUSING TRANSPORT BELT REPLACEMENT Open the front cover and remove the following parts:. a) development unit b) main charger corona c) drum stay d) cleaning unit e) drum flange f) d r u m g) drum guide h) transfer corona unit.
  • Page 81 Remove the front transport gear [G] (1 “E” ring), and the front transport bracket (4 screws). Take off the front transport drive shaft bushing [J], and remove the rear transport gear [K] (1 “E” ring). Separate the transport belt assembly from the rear transport bracket [L] (2 screws), and take off the rear transport drive shaft bushing [M].
  • Page 82 1 Nov. ’87 Y PAD L A C U P P L R E P E M E N T parts: 1. Open the front cover and remove the following a) development unit b) main charger corona unit c) drum stay d) cleaning unit e) drum flange f) drum...
  • Page 83 6-3 OIL BLADE REPLACEMENT 1. Remove the oil supply pad (see 6-2 Oil Supply Pad Replacement). 2. Turn and lift out the oil blade assembly [A]. 3. Separate the blade from the bracket (3 screws) and replace the oil blade. NOTE: Before fitting the oil blade assembly, prime the edge of the blade with silicone oil.
  • Page 84 1 NOV. ’87 6-4 FUSING THERMISTOR REPLACEMENT 1. Remove the oil blade assembly (see 6-3 Oil Blade Replacement). 2. Pull off the fusing knob, turn the silicone oil tank mouth to the front and remove the left inner cover (3 screws). 3.
  • Page 85 N o v . ’ 8 7 THERMOSWITCH REPLACEMENT Turn off the main switch and unplug the copier. Remove the fusing cover (see 6-2 Oil Supply Pad Replacement), and the left inner cover (3 screws). Disconnect the thermoswitch terminal [A] from the lamp control PCB [B] and release the harness from the 2 wire clamps.
  • Page 86 1 Nov. ’87 REPLACEMENT 6-6 HOT ROLLER Turn off the main switch and unplug the copier. Remove the fusing thermistor assembly (see 6-4 Fusing Thermistor Replacement), and the rear cover (2 screws). Un-couple the rear fusing lamp connector [A] and remove the holder [B] (1 screw).
  • Page 87 Place a sheet of paper in between the hot and pressure rollers. Remove the front hot roller gear [1] and bearing [J] (1 “C” ring). Remove the rear hot roller gear [K] (1 “C” ring), taking care that the bear- ing does not drop down and damage the pressure roller.

  • Page 88: Pressure Roller Replacement

    1 Nov. ’87 6-7 PRESSURE ROLLER REPLACEMENT 1. Turn off ;he main switch and unplug the copier. 2. Remove the following covers: a) left inner cover (3 screws) (2 screws) b) rear cover c) lock plate cover (1 screw) screws). d) left cover 3.
  • Page 89 1 Nov. '78 Remove the 2 bushings [D] (1 “E” ring each), and fit them on the new pressure roller [E] . Install the new pressure roller and set it in the pressure release position by lifting the pressure levers [F] and placing two screws [G] in the un- tapped holes (see illustration).
  • Page 90 1 Nov. ’87 6-8 HOT ROLLER STRIPPER REPLACEMENT 1. Open the exit cover and unhook the hot roller stripper springs [A] and remove the strippers [B]. 2. Replace the strippers and fit the springs. NOTE: It is advisable to replace the strippers as a set. 3-48...
  • Page 91 6-9 FUSING PRESSURE ADJUSTMENT 1. Open the exit cover. 2. Move the pressure springs [A] to the desired position as in the table below: Setting Fusing Pressure 12.48 kg 16.88 kg 18.28 kg. NOTE: Make sure the front and rear pressure springs are in the same posi- tion.
  • Page 92 1 Nov. ’87 PAPER EXIT SENSOR REPLACEMENT 6-10 Turn off the main switch and unplug the copier. Remove the following covers: (2 screws) a) rear cover b) lock plate cover (1 screw) (4 screws). c) left cover bracket [A] (2 screws) and disconnect Remove the connector-stopper the exit sensor connector [B].
  • Page 93 1 Nov. ‘87 7. CORONA CORONA WIRE REPLACEMENT Do not handle new corona wires with your bare hands. Oil on the wire will cause uneven charge on the drum. Do not rub the corona wires with rough material (sandpaper, etc.) because the corona wires are carbon-coated.
  • Page 94 1 Nov. ’87 Remove the corona wire [E] from the front end block first. Hook the tension spring [F] on to the new wire and install making sure that the wire is correctly positioned in the “V” slot [G]. Reassemble the wire cleaner, and then the end block covers. 11 .
  • Page 95 ADJUSTMENT 7-2 DRUM CURRENT NOTE: a) The drum currents vary with environmental conditions such as humidity and atmospheric pressure. Generally it is not necessary to adjust the drum currents because they have already been ad- justed for a range of environments at the factory. Drum current adjustment may be required when there are problems with paper separation, incomplete toner transfer, and/or image density.
  • Page 96 1 NOV. ’87 Install the drum shoe and adapter on the drum shaft with the lip to the rear. Route the shoe lead wires out through the development unit opening. Connect the drum shoe and the digital multimeter leads as shown: a) Positive lead to the red lead clip.
  • Page 97 1 Nov. ’87 IL Charge Corona Disconnect CN2 (2p) on the CTB power pack. Slide the drum shoe [A] to its rear limit as shown (X). Position the drum shoe so that the axis of shoe is aligned with the charge corona wire [B] as shown.
  • Page 98 1 Nov. ’87 adjusting screw [F] if the two read- corona wire height 9. Adjust the front front and rear should not be more ings differ. The difference between than 0.2 again. NOTE: After adjusting the front side, confirm the rear reading once Position the drum shoe on the center of the shaft (Z).
  • Page 99 Ill. Transfer Corona 1. Re-install the T/S corona unit and position the drum shoe [A] on the cen- ter of the shaft, so that the axis of the shoe is aligned with the transfer corona wire [B] as shown. 2. Re-install the drum stay [C] (1 screw, 1 knob). Turn on DPS101 -5 (Test Mode) on the main PCB.
  • Page 100 1 NOV. ’87 IV. Separation Corona Position the drum shoe on the center of the shaft so that the axis of the shoe is aligned with the separation corona wire [B] as shown. Re-install the drum stay [C] (1 screw, 1 knob), and return the T/S corona unit to its original position.
  • Page 101 1 NOV. '87 7. Press the “C/S” key and turn off the main switch. switch, press the 10 key “5”, and press “Start”. Confirm the reading is within specifications, however it is not adjustable. ” 9. Press the “C/S” key, turn the main switch and turn off DPS 101-5.
  • Page 102 1 Nov. ’87 8. OTHERS TIMING BELT REPLACEMENT 1. Turn off the main switch and unplug the copier. 2. Remove the following parts: a) development unit b) charge corona unit c) drum stay d) drum flange e) drum f) main PCB (see 1-6 Reverse Clutch Damper Replacement). 3.
  • Page 103 Nov. ‘ W Remove the pulse generator sensor assembly [A] (1 screw, 1 connector) and the pulse generator disk [B] (1 “E” ring). Remove the timing beIt tension bracket [C] together with the bushing [D] (2 Screws). Remove the main motor capacitor [E] (1 screw). Remove the drum shaft bushing [F] (1 “C”...
  • Page 104 1 NOV. ’87 9. COPY IMAGE 9-1 LIGHT INTENSITY ADJUSTMENT NOTE: Original ID sensor adjustment must be made after making the light intensity adjustment. ADJUSTMENT STANDARD: Level 2 of the grey scale on the OS-A4 chart should be just visible on the copy, when the no.2 position (second notch from the dark- est side) of the manual density control is selected.
  • Page 105 5. Open the front cover and remove the left inner cover (3 screws). 6. Adjust VR101 on the lamp control PCB [A], to achieve correctly i l - luminated copies. 7. Close the front cover and make test copies. 8. Confirm that the image density is within the standard. NOTE: Check and adjust the light intensity at every visit.
  • Page 106 1 Nov. ’87 9-2 ORIGINAL IMAGE DENSITY SENSOR ADJUSTMENT ADJUSTMENT STANDARD: 2.5 V ±0.I V (7F t5) PREPARATION: Turn off the main switch. Move the 1st scanner [A] to the central area of the optics unit by remov- ing the exposure glass and sliding the scanner rod to the right. Re-install the exposure glass.
  • Page 107 N o v 8. If the voltage is incorrect, adjust VR101 on the main PCB in order to ob- tain the correct amount. 9. Press the “C/S” key, turn off the main switch and DPS 101-5. after being on for 20 NOTE: The exposure lamp has a safety shut-off seconds.
  • Page 108 1 Nov. ’87 9-3 HORIZONTAL MAGNIFICATION ADJUSTMENT “ 1. Make a few copies using an OS-A4 test chart [A] as the original and check the horizontal magnification. magnification is out of specification, adjust it in the following man- 2. If the ner: Remove the rear and upper covers.
  • Page 109 ’87 NOV. REGISTRATION TIMING ADJUSTMENT 1. Place a scale graduated in millimeters on the exposure glass, aligning it left scale. with Make 3 copies with the no.7 position of the manual image density con- trol selected. 3. Adjust the registration timing using the DPS 101-1, -2, -3, and -4 on the main PCB as per the above table.
  • Page 110 1 Nov. ’87 9-5 UNEVEN IMAGE DENSITY ADJUSTMENT (Uneven exposure) NOTE: The exposure lamp position adjustment should be made before this procedure. The side to side variation of the grey scales ADJUSTMENT STANDARD: should be less than 1 level. 1. Make a few copies using an OS-A4 test chart [A]. 2.
  • Page 111 SECTION 4 TROUBLESHOOTING...

  • Page 113: Copy Quality

    1 Nov '87 1. COPY QUALITY 1-1 WHITE SPOTS 1. FIREFLY SPOTS - Possible Causes - . Developer too old Insufficient toner in the developer Dirty seals around the development unit - Action - Is there a small black spot in the center of the white spot? Check and adjust the doctor gap (0.72 mm).
  • Page 114 1 NOV. ’87 SPOTS Causes - . Dirty corona wires Incorrect corona currents Is the charge correct? Adjust current. Clean the transfer corona wire and adjust the transfer current.
  • Page 115 1-2 HAT IMAGE - Possible Causes - Defective quenching lamp Charge corona wire miscounted Incorrect corona current Old developer - Action - Does the quenching lamp turn on? PCB? Replace the AC drive PCB. Replace the quenching lamp. the charge corona wire properly installed? Install the charge corona wire correctly.
  • Page 116 1 Nov. ’87 1-3 BLANK AREA OR PATCHY IMAGE - Possible Causes - Dirty PTL, transfer or separation coronas. - Action - Are the transfer and separation corona wires improperly installed? Clean the PTL, transfer and separation corona wires and adjust the corona currents Clean and reset the wire(s).
  • Page 117 1 Nov. '87 VERTICAL WHITE LINES OR BANDS 1. LINES 78 mm APART - Possible Causes - Damaged pick-off pawls Pick-off mechanism malfunction - Action - Does the pick-off pawl mechanism work correctly? Correct or replace any defective parts. Are the pick-off pawls damaged? Replace the drum.
  • Page 118 1 Nov. ’87 - Action - Start a copy cycle and stop it before the copy reaches the fusing unit. Do the same lines exist on the unfused copy? If the surface of the hot roller is scratched, which part is scratching the hot roller surface? Oil Blade Hot Roller Strippers...
  • Page 119 1 N o v . ’ 8 7 3. FUZZY LINES OR BANDS Possible Causes - . Dirty corona wire Dirty brush seals Action - Clean the charge and transfer corona wires. Clean all brush seals that contact the drum. If the drum is brand-new, make “Free Run”...
  • Page 120 1 Nov. ’87 1-6 UNEVEN DENSITY 1. IMAGE DENSITY GRADUALLY CHANGES ACROSS THE COPY - Possible Causes - Charge corona wire height not even Charge corona wire dirty . Doctor gap not even - Action - Are any of the optics parts dirty? Toner Shield Glass Exposure Glass Mirrors, Lens, Reflectors...
  • Page 121 1 Nov. '87 2. UNEVEN DENSITY APPEARS IN BANDS. - Possible Causes - . Exposure lamp misaligned . Dirty quenching lamp . Dirty corona wire Incorrect corona current - Action - Are any of the following parts stained or dirty? Is the exposure lamp stained? Correct using the adjusting plates.
  • Page 122 1 Nov. ’87 ABNORMAL IMAGE DENSITY IMAGE DENSITY IS TOO HIGH OR TOO LOW - Possible Causes - Incorrect charge corona current . ID sensor malfunction D sensor. Is the voltage correct? it is within specifications. Check and adjust the charge corona current. If the image density is too light, use serviceman mode (toner feed mode) to supply toner.
  • Page 123 1 Nov. ’87 VERTICAL BLACK LINES OR BANDS 1. DOTTED LINES OR BANDS - Possible Causes - Pick-off pawl mechanism malfunction . Scratched drum - Action - Do the pick-off pawls swing properly? Correct or replace the pick-off pawls and replace the drum. Is the gap between the drum and pick-off pawls incorrect (1 to 2 mm)? If the pick-off paw! mechanism does not work properly, correct or replace any defective parts.
  • Page 124 1 Nov. ’87 3. STRAIGHT LINES OR BANDS - Possible Causes - Hot roller scratched Insufficient silicone oil Cleaning blade damaged Drum scratched Dust between the cleaning blade and drum Edge of the cleaning blade deformed Insufficient cleaning pressure Cleaning mechanism not working properly - Action - and stop it just before the paper reaches the fusing unit.
  • Page 125 Correct or replace any defective parts and check their operation again. Is the edge of the cleaning blade deformed? PawIs), and replace the drum. 4-13...
  • Page 126 1 Nov. ’87 BLACK SPOTS 1. AT THE LEADING EDGE - Possible Cause - Separation corona wire miscounted Incorrect transfer corona current - Action - Is the separation corona wire properly installed? Reset the transfer corona wire and clean the separation corona wire and T/S corona unit.
  • Page 127 1 Nov. ’87 DIRTY BACKGROUND ON ENTIRE COPY IMAGE 1-10 Possible Causes - Incorrect exposure lamp output Inefficient drum cleaning Development bias malfunction Toner supply clutch malfunction Incorrect corona current Doctor gap too large Quenching lamp open Dirty optics - Action - Clean the optics and the quenching lamp.
  • Page 128 1 Nov. ’87 Check that the development roller shaft contacts the bias plate at the rear of the machine. Replace the CTB power pack or the main PCB. Is the doctor gap correct? Adjust the doctor gap. Are both the charge and the transfer corona currents within specifications? Adjust the currents.
  • Page 129 1-11 BLANK COPY Possible Causes - Charge corona wire miscounted or broken . Defective CTB power pack Defective main PCB - Action - Is there a faint image? Is the charge corona wire (or unit) incorrectly installed? Does the main PCB output the correct charge trigger signal to the CTB power pack (CN114-3 drops from +24 volts to ground)? Replace the main PCB.
  • Page 130 1 Nov. ’87 Replace the main PCB. Replace the CTB power pack. Reset the transfer corona wire (unit). Check the development drive mechanism and clean or replace any defective parts. 4-18...
  • Page 131 1 Nov. ’87 1-12 LIGHT COPY - Possible Causes - Incorrect exposure lamp output Development bias malfunction Incorrect corona currents Narrow doctor gap - Action - Is appropriate development bias being applied? Replace the CTB power pack or the main PCB. Is the doctor gap correct? Adjust the doctor gap.
  • Page 132 Nov. ’87 1-13 UNFUSED COPY IMAGE CAN BE EASILY RUBBED Possible Causes - Thermistor malfunction Very low early morning temperatures. rough surface. Copy paper has a very Action - Does the problem occur only early in the morning? Is the thermistor damaged? increase the fusing Replace the thermistor.
  • Page 133 1-14 JITTER - Possible Causes - Vibration in the drive mechanism Scanner not moving smoothly Reverse clutch damper damaged - Action - Does jitter appear around 40 mm from the trailing edge? (Around 20 mm from the trailing edge on copying.) 81/2' x 11”...

  • Page 134: Service Call Conditions

    1 Nov. ’87 2. SERVICE CALL CONDITIONS E1 EXPOSURE - Definition - Lights if the input from the original ID sensor is less than 0.3 volt for ap- proximately 1 second after the exposure lamp turns on. - Possible Causes - Exposure lamp broken Original ID sensor broken Lamp control PCB defective...
  • Page 135 2-2 E2 SCANNER DRIVE - Definition - . Lights if the scanner home position sensor does not turn on within 10 seconds after the “Start” key is pressed. . Lights if the scanner home position sensor does not turn off within 3 seconds after the scanner starts moving.
  • Page 136 1 Nov. ’87 FUSING 2-3 E5 - Definition - Lights if the hot roller temperature does not increase at Ieast 2 degrees C within 10 seconds after the power is turned on. Lights if the hot roller temperature does not reach 140 degrees C within 75 seconds after the power is turned on.
  • Page 137 ’87 1 Nov. Does CN114-6 drop from +24 volts to O volt when the power is turned on? Replace the lamp control PCB. Replace the main PCB. 4 - 2 5...
  • Page 138 1 Nov. ’87 2-4 E6 FUNCTIONAL DRIVE - Definition - . Lights if the CPU receives no pulse from the pulse generator for a 0.7 second interval. - Possible Causes - Timing belt broken or out of position Pulse generator sensor failure .
  • Page 139 2-5 E7 TONER OVERFLOW - Definition - Lights if the used toner in the used toner tank actuates the toner overflow sensor. - Possible Causes - Used toner tank is full of used toner . Toner overflow sensor failure . Main PCB defective. - Action - Is the used toner tank full of used toner? Dispose of the used toner.
  • Page 140 1 Nov. ’87 2-6 IMAGE DENSITY INDICATOR - Definition - . Blinks if Vsg becomes less than 2.5 volts. Blinks becomes more than 2.5 volts. if Vsp - Possible Causes - . Dirty image density sensor Image density sensor failure Main PCB defective.
  • Page 141 DEFECTIVE SENSOR/SWITCH TABLE Problem Name Condition Symbol Self-diagnostic code “E6” Pulse Generator Open lights. ” Sensor Same as “Open” condition. Short The CPU will not detect Toner End Open toner end in toner end Sensor condition. Same as “Open” condition. Short The copier will not shift to Open...
  • Page 142 1 Nov. Problem Condition Name Symbol Paper always jams at the Open Paper Exit Sensor paper exit roller. “Check Paper Path” Short indicator lights when the main switch is turned on. Self-diagnostic code “E2” Open Scanner Home lights. Position Sensor Short Same as “Open”...
  • Page 143 1 Nov. ’87 Problem Condition Name Symbol Copier can not be Open Door Switch powered. Copier can not be depowered even when the front cover or the exit cover is opened. Open User code “U3” lights even Development when the development unit Set Switch is in the copier.