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Ricoh A151, Field Service Manual

The Ricoh A151 Field Service Manual is a comprehensive guide for service technicians, ensuring efficient maintenance and repairs. This essential manual is available for immediate download, free of charge, from our website. Maximize the potential of your Ricoh A151 with this detailed technical resource.

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8.13 REGISTRATION ADJUSTMENT  .   .   .   .   .   .   .   .   .   .   .   .  5-83

8.14 SIDE-TO-SIDE REGISTRATION ADJUSTMENT  .   .   .   .   .   .  5-84

8.15 4TH/5TH MIRROR HEIGHT ADJUSTMENT

 .   .   .   .   .   .   .  5-87

9. OTHERS  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   5-88

9.1 OZONE FILTER REPLACEMENT  .   .   .   .   .   .   .   .   .   .   .   .  5-88

9.2 220

∼

230/240V CONVERSION  .   .   .   .   .   .   .   .   .   .   .   .   .  5-89

9.3 OPTIONAL EQUIPMENT INSTALLATION  .   .   .   .   .   .   .   .   .  5-90

9.3.1 Optics Anti-condensation Heater Installation  .   .   .   .   .   .  5-90

9.3.2 Drum Anti-condensation Heater Installation   .   .   .   .   .   .  5-91

9.3.3 Pre-transfer Lamp (PTL) Installation  .   .   .   .   .   .   .   .   .  5-92

9.3.4 Optics Cooling Fan Installation (FT3013 Copier Only)  .   .  5-93

9.4 TORSION BAR FORCE ADJUSTMENT .   .   .   .   .   .   .   .   .   .  5-94

SECTION 6 TROUBLESHOOTING

1. COPY QUALITY  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   6-1

1.1 BLANK COPY (WHITE COPY)  .   .   .   .   .   .   .   .   .   .   .   .   .  6-1

1.2 DIRTY BACKGROUND  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-4

1.3 UNEVEN IMAGE DENSITY

 .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-7

1.4 VERTICAL BLACK BANDS   .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-8

1.5 VERTICAL BLACK LINES   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-9

1.6 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED) 6-10

1.7 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINCT)  .  6-11

1.8 HORIZONTAL BLACK/WHITE LINES .   .   .   .   .   .   .   .   .   .   .  6-12

1.9 JITTER

 .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-13

1.10 BLACK SPOTS ON THE COPY IMAGE  .   .   .   .   .   .   .   .   .  6-14

1.11 SKEWED (OPTICAL) COPY IMAGE

 .   .   .   .   .   .   .   .   .   .  6-15

1.12 TONER DENSITY TOO HIGH  .   .   .   .   .   .   .   .   .   .   .   .   .  6-16

1.13 TONER DENSITY TOO LOW  .   .   .   .   .   .   .   .   .   .   .   .   .  6-18

1.14 TONER SCATTERING  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .  6-20

A151/A152/A202/A203

vi

FSM

Summary of Contents for A151

Page 1: ...SERVICE MANUAL PN RCFM3213 A151 A152 A202 A203 RICOH GROUP COMPANIES ...

Page 2: ...SERVICE MANUAL A151 A152 A202 A203 RICOH GROUP COMPANIES ...

Page 3: ...A151 A152 A202 A203 FIELD SERVICE MANUAL PN RCFM3213 ...

Page 4: ......

Page 5: ...ERMISSION OF RICOH CORPORATION All product names domain names or product illustrations including desktop images used in this document are trademarks registered trademarks or the property of their respective companies They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies No such use or the use of any trade name or web site is intended...

Page 6: ......

Page 7: ...poration Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury damage to property or loss of warranty protection Ricoh Corporation WARNING ...

Page 8: ......

Page 9: ...STETNER RICOH SAVIN A151 2613 FT3013 9013 A152 2613Z FT3213 9013Z A202 2713 FT3513 9113 A203 2613 FT3713 9013Z DOCUMENTATION HISTORY REV NO DATE COMMENTS 9 94 Original Printing 1 6 96 Reprint 2 4 97 A202 A203 Addition 3 7 98 Reprint ...

Page 10: ......

Page 11: ...ION 3 INSTALLATION 1 INSTALLATION REQUIREMENTS 3 1 1 1 ENVIRONMENT 3 1 1 2 MACHINE LEVEL 3 1 1 3 MINIMUM SPACE REQUIREMENTS 3 2 1 4 POWER REQUIREMENTS 3 2 2 INSTALLATION PROCEDURE 3 3 2 1 ACCESSORY CHECK 3 3 2 2 COPIER INSTALLATION PROCEDURE 3 4 2 3 KEY COUNTER HOLDER INSTALLATION OPTION 3 10 SECTION 4 SERVICE TABLES 1 SERVICE REMARKS 4 1 1 1 GENERAL CAUTION 4 1 1 2 DRUM 4 1 1 3 CHARGE CORONA 4 2 ...

Page 12: ...r Modes 4 9 2 1 3 Memory Clear Procedure 4 10 2 2 SERVICE PROGRAM MODE TABLE 4 13 2 3 SP MODE 8 INPUT CHECK 4 21 2 4 SP MODE 9 OUTPUT CHECK 4 22 2 5 SERVICE CALL AND USER CODE TABLE 4 23 3 SERVICE TABLES 4 25 3 1 TEST POINTS 4 25 3 2 DIP SWITCHES AND JUMPER SWITCHES 4 26 3 3 VARIABLE RESISTORS 4 27 4 SPECIAL TOOLS AND LUBRICANTS 4 28 5 PREVENTIVE MAINTENANCE SCHEDULE 4 29 5 1 PM TABLE 4 29 5 2 EXP...

Page 13: ... Lower Rear Cover 5 2 1 1 7 Upper Cover 5 3 1 2 INNER COVER REMOVAL 5 4 2 OPTICS 5 5 2 1 EXPOSURE GLASS REMOVAL 5 5 2 2 1ST MIRROR REMOVAL 5 6 2 3 2ND AND 3RD MIRROR REMOVAL 5 8 2 4 4TH AND 5TH MIRROR REPLACEMENT 5 10 2 5 EXPOSURE LAMP REPLACEMENT 5 11 2 6 THERMOFUSE REPLACEMENT 5 13 2 7 SCANNER DRIVE WIRE REPLACEMENT 5 14 2 7 1 Wire Removal 5 14 2 7 2 Wire Installation 5 15 2 8 SCANNER MOTOR REPL...

Page 14: ... 5 35 5 1 FEED ROLLER REPLACEMENT 5 35 5 2 PAPER TRAY SWITCH REPLACEMENT 5 37 5 3 RELAY SENSOR AND REGISTRATION SENSOR REPLACEMENT 5 38 5 4 RELAY ROLLER CLUTCH PAPER FEED CLUTCH AND REGISTRATION CLUTCH REPLACEMENT 5 40 6 AROUND THE DRUM 5 42 6 1 DRUM REPLACEMENT 5 42 6 2 QUENCHING LAMP REPLACEMENT 5 44 6 3 ERASE LAMP REPLACEMENT 5 45 6 4 CHARGE CORONA WIRE REPLACEMENT 5 46 6 5 CHARGE CORONA GRID P...

Page 15: ...TCH REPLACEMENT 5 70 7 7 FUSING THERMISTOR REPLACEMENT 5 71 7 8 FUSING PRESSURE ADJUSTMENT 5 72 8 COPY QUALITY ADJUSTMENT 5 73 8 1 LIGHT INTENSITY ADJUSTMENT 5 74 8 2 SIDE TO SIDE EXPOSURE ADJUSTMENT 5 75 8 3 IMAGE BIAS VOLTAGE ADJUSTMENT 5 76 8 4 TONER DENSITY ADJUSTMENT 5 77 8 5 FIXED TONER SUPPLY MODE SELECTION 5 77 8 6 TONER SUPPLY RATIO SELECTION 5 77 8 7 ID SENSOR Vsg ADJUSTMENT 5 78 8 8 ADS...

Page 16: ...an Installation FT3013 Copier Only 5 93 9 4 TORSION BAR FORCE ADJUSTMENT 5 94 SECTION 6 TROUBLESHOOTING 1 COPY QUALITY 6 1 1 1 BLANK COPY WHITE COPY 6 1 1 2 DIRTY BACKGROUND 6 4 1 3 UNEVEN IMAGE DENSITY 6 7 1 4 VERTICAL BLACK BANDS 6 8 1 5 VERTICAL BLACK LINES 6 9 1 6 VERTICAL WHITE LINES OR BANDS 1 DULL OR BLURRED 6 10 1 7 VERTICAL WHITE LINES OR BANDS 2 THIN DISTINCT 6 11 1 8 HORIZONTAL BLACK WH...

Page 17: ... 2 8 CODE 2A 4TH 5TH MIRROR HOME POSITION ERROR FT3213 COPIER ONLY 6 37 2 9 CODE 2B 4TH 5TH MIRROR HOME POSITION ERROR FT3213 COPIER ONLY 6 39 2 10 CODE 40 OPTICS THERMISTOR ERROR 6 41 2 11 CODE 52 FUSING WARM UP ERROR 6 42 2 12 CODE 53 FUSING OVERHEAT 6 44 2 13 CODE 55 FUSING THERMISTOR OPEN 6 45 2 14 CODE 96 DF TIMING PULSE ERROR 6 47 2 15 DF COMMUNICATION ERROR 6 49 2 16 ABNORMAL CONDITION IN T...

Page 18: ...ICK UP ROLLER REPLACEMENT 7 11 4 4 FEED ROLLER REPLACEMENT 7 12 4 5 FRICTION BELT REPLACEMENT 7 13 4 6 PICK UP SOLENOID ADJUSTMENT 7 14 SECTION 8 A202 A203 COPIER MAJOR DIFFERENCES BETWEEN THE A202 A203 AND A151 A152 COPIERS 1 1 SPECIFICATIONS 8 1 2 COPY PROCESS CONTROL 8 4 3 MECHANICAL COMPONENT LAYOUT 8 5 4 ELECTRICAL COMPONENT LAYOUT 8 6 5 ELECTRICAL COMPONENT DESCRIPTIONS 8 7 6 DRIVE LAYOUT 8 ...

Page 19: ...PLY AND AGITATOR DRIVE MECHANISM 8 18 12 PAPER FEED 8 19 12 1 PAPER LENGTH DETECTION Paper Feed Station 8 19 13 IMAGE FUSING 8 20 13 1 FUSING LAMP CONTROL CIRCUIT 8 20 13 2 OVERHEAT PROTECTION 8 20 14 INSTALLATION 8 21 14 1 COPIER A202 A203 ACCESSORY CHECK 8 21 14 2 COPIER A202 A203 INSTALLATION PROCEDURE 8 22 14 3 DOCUMENT FEEDER A662 ACCESSORY CHECK 8 28 14 4 DOCUMENT FEEDER A662 INSTALLATION PR...

Page 20: ...T 8 54 18 4 GRID VOLTAGE ADJUSTMENT SP9 46 8 55 18 5 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT SP9 38 8 56 18 6 TRANSFER CORONA CURRENT ADJUSTMENT SP9 5 8 57 18 7 SEPARATION CORONA CURRENT ADJUSTMENT SP9 6 8 58 SECTION 9 DOCUMENT FEEDER A662 1 SPECIFICATIONS 9 1 2 COMPONENT LAYOUT 9 2 2 1 MECHANICAL COMPONENTS 9 2 2 2 ELECTRICAL COMPONENTS 9 2 3 ELECTRICAL COMPONENT DESCRIPTIONS 9 3 4 POWER DISTRIBUTION...

Page 21: ... SERVICE TABLES 9 13 8 1 DIP SWITCHES 9 13 8 2 VARIABLE RESISTORS 9 13 8 3 FUSE 9 13 9 REPLACEMENT AND ADJUSTMENT 9 14 9 1 TRANSPORT BELT REPLACEMENT 9 14 9 2 FEED IN UNIT REMOVAL 9 16 9 3 PICK UP ROLLER REPLACEMENT 9 17 9 4 FEED ROLLER REPLACEMENT 9 18 9 5 FRICTION BELT REPLACEMENT 9 19 9 6 PICK UP SOLENOID ADJUSTMENT 9 20 FSM xi A151 A152 A202 A203 ...

Page 22: ......

Page 23: ...eep hands away from the mechanical and the electrical components to avoid any injury 6 If the start key is pressed before the copier completes the warm up period Ready indicator starts blinking keep hands away from the mechanical and the electrical components as the copier starts making copies as soon as the warm up period is completed 7 The inside and the metal parts of the fusing unit become ext...

Page 24: ...tery Used batteries must be handled in accordance with local regulations SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Do not incinerate the toner cartridge or the used toner Toner dust may ignite suddenly when exposed to open flame 2 Dispose of used toner developer and organic photoconductor according to local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance with lo...

Page 25: ... 5 TAB POSITION 6 TAB POSITION 7 TAB POSITION 8 A151 A152 OVERALL MACHINE INFORMATION DOCUMENT FEEDER A662 A151 A152 GUIDE TO COMPONENTS A151 A152 INSTALLATION A151 A152 SERVICE TABLES A151 A152 REPLACEMENT AND ADJUSTMENT A151 A152 TROUBLESHOOTING DOCUMENT FEEDER A296 A202 A203 SERVICE MANUAL ...

Page 26: ......

Page 27: ...OVERALL MACHINE INFORMATION ...

Page 28: ......

Page 29: ... 90 g m2 17 to 24 lb Bypass feed 52 to 105 g m2 14 to 28 lb Reproduction Ratios 2 Enlargement and 3 Reduction FT3213 copier only A4 Version Letter Version Enlargement 141 122 129 121 Full size 100 100 Reduction 93 82 71 93 74 65 Zoom From 61 to 141 in 1 steps FT3213 copier only Copying Speed 13 copies minute A4 81 2 x 11 lengthwise 10 copies minute B4 81 2 x 14 Warm Up Time 30 seconds at 20 C 68 F...

Page 30: ...al number plate rating plate to determine the power source required by the machine Power Consumption Copier Only With DF Maximum 1 4 kVA 1 5 kVA Warm up 620 VA average 640 VA average Copy cycle 810 VA average 860 VA average Ready 160 VA average 180 VA average Noise Emission Copier Only With DF Maximum 58 db 60 db Copy cycle Less than 55 db Less than 55 db Ready Less than 39 db Less than 39 db Dime...

Page 31: ...ier only Key counter Optional Equipment Service items Drum anti condensation heater Optics anti condensation heater Pre transfer lamp Optics cooling fan for FT3013 copier only Specifications are subject to change without notice Model Designation A151 FT3013 A152 FT3213 OVERALL MACHINE INFORMATION FSM 1 3 A151 A152 ...

Page 32: ......

Page 33: ...GUIDE TO COMPONENTS ...

Page 34: ......

Page 35: ... 9 Hot Roller 10 Exit Rollers 11 Copy Tray 12 Hot Roller Strippers 13 Exhaust Blower Motor 14 3rd Mirror 15 2nd Mirror 16 1st Mirror 17 Ozone Filter 18 Used Toner Tank 19 Cleaning Blade 20 Quenching Lamp 21 Charge Corona Unit 22 Lens 23 6th Mirror 24 Erase Lamp 25 Drum 26 4th Mirror 27 5th Mirror 28 Optics Cooling Fan Motor FT3213 Copier only 29 Toner Supply Unit 30 Development Unit 31 2nd Relay R...

Page 36: ...using Thermoswitch 16 Exit Sensor 17 Exhaust Blower Motor 18 Optics Thermofuse 19 Auto Image Density Sensor 20 Fusing Thermistor 21 Exposure Lamp 22 Lens Motor FT3213 copier only 23 Scanner Home Position Sensor 24 Optics Thermistor 25 Lens Home Position Sensor FT3213 copier only 26 Power Pack CC Grid Bias 27 AC Drive Board 28 Fusing Triac 115 V only 29 Scanner Motor 30 4th 5th Mirror Home Position...

Page 37: ...n dc stepper FT3213 copier only 31 M5 Optics Cooling Fan Motor Prevents built up of hot air in the optics cavity 24 Vdc FT3213 copier only 4 M6 Exhaust Blower Motor Removes heat from around the fusing unit and moves the ozone built up around the charge section to the ozone filter 24 Vdc 17 Magnetic Clutch SYMBOL NAME FUNCTION INDEX NO MC1 Registration Clutch Drives the registration rollers 3 Magne...

Page 38: ...ects misfeeds 2 Controls the relay roller clutch stop timing 5 S5 Exit Sensor Detects misfeeds 16 S6 Relay Sensor 1 Detects when copy paper is set on the by pass feed table 2 Detects misfeeds 2 S7 Image Density ID Sensor Detects the density of the image on the drum to control the toner density 6 S8 Auto Image Density Sensor ADS Senses the background density of the original 19 Printed Circuit Board...

Page 39: ...Pack TC SC Provides high voltage for the transfer and separation corona 7 Counter SYMBOL NAME FUNCTION INDEX NO CO1 Total Counter Keeps track of the total number of copies made 10 Others SYMBOL NAME FUNCTION INDEX NO TH1 Fusing Thermistor Monitors the fusing temperature 20 TH2 Optics Thermistor Monitors the optics temperature 24 TS Fusing Thermoswitch Provides back up overheat protection in the fu...

Page 40: ... Pulley G12 Development Gear G13 Relay Gear G14 Toner Supply CL Gear Toner Supply CL G2 Relay Gear G8 Relay Gear Cleaning Unit G3 Fusing Drive Gear G4 Hot Roller Gear G7 Relay Gear G5 Exit Roller Gear G6 Relay Gear Development Unit Fusing and Exit Unit Toner Supply Unit B BP6 BP5 TB1 TB3 G24 G22 BP1 G21 G20 G19 G18 G17 G16 G15 G14 G13 G12 G11 G10 G9 G8 G7 G6 G4 BP2 G5 G3 G2 G1 G23 G26 G9 TB2 G8 G1...

Page 41: ...Timing Belt Drive Gear BP3 Timing Belt Pulley TB2 Timing Belt BP4 Timing Belt Pulley G25 Relay Gear G26 Drum Drive Gear A Registration CL Registration Rollers G20 Relay Gear G17 Relay Roller CL Gear Relay Roller CL G16 2nd Relay Roller Gear 2nd Relay Rollers 1st Relay Rollers G18 Relay Gear G19 1st Relay Roller Gear B GUIDE TO COMPONENTS FSM 2 7 A151 A152 ...

Page 42: ......

Page 43: ...INSTALLATION ...

Page 44: ......

Page 45: ...ere it will not be subjected to sudden temperature changes b Where it will not be directly exposed to cool air from an air conditioner in the summer c Where it will not be directly exposed to reflected heat from a space heater in winter 7 Avoid placing the machine in an area filled with corrosive gas 8 Avoid any places higher than 2000 meters 6500 feet above sea level 9 Place the machine on a stro...

Page 46: ...ge level 110 V 60 Hz More than 15 A 115 V 60 Hz More than 15 A U S Version 220 240 V 50 Hz More than 8 A 220 V 60 Hz More than 8 A 220 V 50 Hz More than 8 A 2 Permissible voltage fluctuation 10 3 Do not set anything on the power cord NOTE a Be sure to ground the machine Do not connect the grounding wire to a gas pipe b Make sure the plug is firmly inserted in the outlet c Avoid multi wiring 10 cm ...

Page 47: ...condition of the accessories in the box according to the following list 1 Copy Tray 1 2 Envelope for NECR 17 Only 1 3 NECR 1 4 Operating Instructions Except 27 1 5 Decal Symbol Explanation 1 6 User Survey Card 17 Only 1 NOTE 17 U S Version INSTALLATION FSM 3 3 A151 A152 ...

Page 48: ...2 2 COPIER INSTALLATION PROCEDURE 1 Remove the strips of tape from the copier as shown 2 Pull out the paper tray A then remove the foam block B and tapes Close the paper tray A B A151 A152 3 4 FSM ...

Page 49: ...se 6 Open the upper unit G by pressing the release lever H See Caution below Gently remove the shipping spacers I from both ends of the transfer separation corona unit J Remove the strip of tape K and close the upper unit CAUTION Be sure to place and hold your left hand on top of the upper unit while pushing the release lever to the right with your right hand The upper unit will raise with force a...

Page 50: ... the gears F on both sides to distribute the developer evenly as shown in the illustration NOTE This copier is not equipped with a knob on the paddle roller shaft like other machines When installing new developer or manually rotating the development roller always make sure to turn the gears in the direction shown in the illustration above The copier might be damaged if they are turned in the oppos...

Page 51: ...lose the front cover CAUTION This procedure step 14 must be done only in 240 volt areas 14 Perform the conversion from 220 230 V to 240 V as follows 1 Remove the upper rear cover C 2 screws 2 Disconnect the short connector D 2P White on the ac drive board E from CN421 and reconnect it to CN421 as shown in the illustration 3 Reinstall the upper rear cover A B A 240V D E 220 230V CN421 C INSTALLATIO...

Page 52: ...using numeral key Then press the Auto Image Density key 12 will start blinking Go to the step 15 3 15 Perform the developer initial setting 1 Plug in the machine and turn on the main switch then lower the platen cover 2 Enter the SP mode as follows a Enter 71 using the numeral keys b Press and hold the Clear Stop key until a dot appears in the top left corner of the copy counter c Release the Clea...

Page 53: ...chine place the decal on the DF as shown 17 Install the copy tray C 18 Load paper into the paper tray D according to the instructions on the paper tray 19 Change the paper size plate E to display the correct paper size 20 Check the machine operation and copy quality C A A B D E INSTALLATION FSM 3 9 A151 A152 ...

Page 54: ...ews 7 Install the key counter harness B to CN121 on the main board 8 Connect the 4P connector D of the key counter holder E to the key counter harness B through the key counter access hole 9 Position the key counter bracket A as shown in the illustration and insert the key counter holder 10 Align the holes in the key counter bracket with the mounting holes of the key counter holder and secure the ...

Page 55: ...SERVICE TABLES ...

Page 56: ......

Page 57: ...and when releasing it from the lower unit It is also important that the operator also be familiar with the proper method of releasing the upper unit This condition is not a concern if the DF is installed to the FT3213 4 Due to variation in the tolerance of the torsion springs the upper unit cannot hold at an angle of 16 degrees by itself when the DF is installed To avoid possible injury always use...

Page 58: ...ean the corona wire by sliding the corona unit in and out The cleaner pads come into contact with the corona wire when the corona unit is slid all the way out The wire and casing can also be cleaned with water or dry cloth Do not use any abrasives or solvents 2 Do not touch the corona wire and the grid plate with oily hands Oil stains may cause uneven image density on copies 3 Make sure that the c...

Page 59: ...ss is positioned on the right hand side facing upward This side has received a special treatment to make it smoother and generate less static electricity This is especially important when the DF is installed 4 Clean the following parts with a dry cloth a Lens and 4th 5th Mirror Guide Rails b Scanner Guide Plates 5 Only use a clean soft cloth damped with alcohol or water to clean the mirrors and le...

Page 60: ... proper gap between the doctor blade and the development roller 5 Clean the drive gears after removing used developer 6 Developer initial setting SP65 is necessary when the developer is replaced 7 Dispose of used developer according to local regulations 8 When installing new developer or manually rotating the development roller always make sure to turn the gears in the direction shown in Sec 5 Dev...

Page 61: ... into the copier be sure that the cleaning unit rail is properly engaged with the unit guide rail on the copier 5 Empty the used toner tank every service call and clear the toner end counter SP58 by SP83 toner end counter clear Especially since the FT3013 copier does not have side erasing by the erase lamp the used toner tank may become full in a faster period than expected under certain condition...

Page 62: ...oard remove the RAM pack from the old main board and place it on the new main board Then install the new main board in the copier 2 After installing a new main board with a new RAM pack the Clear All Memory SP99 procedure see page 4 10 must be performed Do not perform SP99 if you have placed the old RAM pack on the new main board 3 Never perform SP99 Clear All Memory except for the following two c...

Page 63: ...ower Pack CC Grid Bias Power Pack 8 The RAM pack must be handled as follows WARNING The RAM pack has a lithium battery which can explode if handled incorrectly Replace only with the same type RAM pack Do not recharge or burn this battery Used RAM pack must be handled in accordance with local regulations SERVICE TABLES FSM 4 7 A151 A152 ...

Page 64: ...eys 3 Press and hold the Clear Stop key until a dot appears in the top left corner of the Copy Counter and then release it 4 Press the Clear Stop key again and then press the Lighter key NOTE 5 will blink in the Copy Counter to show that the SP mode has been accessed 5 Enter the desired SP mode number using the numeral keys The SP mode numbers are given in the Service Program Mode Table NOTE is di...

Page 65: ... Auto Image Density key 2 1 2 Change Adjustment Values or Modes 1 Follow the steps from 1 to 6 in Access Procedure 1 or the steps from 1 to 4 in access procedure 2 2 The factory set or the default setting will be displayed in the Magnification indicator FT3213 copier or in the Copy Counter FT3013 copier 3 Enter the desired value or mode using the numeral keys and then press the Auto Image Density ...

Page 66: ...122 Exposure Lamp Service Calls SP124 Fusing Section Service Calls SP125 DF Communication Service Calls 1 Turn off the main switch 2 Turn on DPS101 2 and short circuit JPS101 C Lower 3 Turn on the main switch 4 Enter 98 by the numeral keys and then press the Auto Image Density key to view data 5 Enter 1 by the numeral key and then press the Auto Image Density key NOTE The data 1 blinks 4 times whe...

Page 67: ... has been cleared See Used Toner Removal CAUTION Skipping this step will cause the used toner overflow condition not to be detected properly 7 Replace the OPC drum with a new one See Drum Replacement CAUTION Since the drum motor rotation time SP57 for the drum wear correction has been cleared the old drum cannot be used If the old drum is used after all memory is cleared dirty background may occur...

Page 68: ...age Adjustment 5 SP54 Vsg Adjustment 6 SP42 Registration Adjustment 7 SP41 Leading Edge Erase Margin Adjustment 8 SP43 Vertical Magnification Adjustment 9 SP44 Horizontal Magnification Adjustment FT3213 copier only 10 SP47 Focus Adjustment FT3213 copier only 11 Turn off the main switch 12 Turn off DPS101 2 and open circuit JPS101 C Lower A151 A152 4 12 FSM ...

Page 69: ...ensity key in Ready mode to turn off this mode Use this mode to check whether the paper misfeed was caused by a sensor malfunction The total counter increments when copies are made in this mode 7 Aging Mode Factory use 8 Input Check Displays the input data from sensors and switches For data see page 4 20 9 Output Check Electrical components turn on For data see page 4 21 11 All Indicators ON Turns...

Page 70: ...2 Vo 20V 3 Vo 40V 34 ADS Level Selects the image density level in ADS mode 0 Normal 1 Darker 2 Lighter Data 1 Increases grid voltage 40V Development bias voltage is not changed Data 2 Increases development bias voltage 40V Grid voltage is not changed 35 ID Detection Interval ID sensor check is performed every 5 copies or 10 copies 0 10 copies 1 5 copies If low image density occurs in the near end ...

Page 71: ... 0 Vo 1 Vo 40V 2 Vo 40V 3 Vo 80V 51 Exposure Lamp Data Display Displays the exposure lamp data with a reference number 100 150 The exposure lamp and optics cooling fans turn on for 10 seconds when the Auto Image Density key is pressed Press the C S key to turn this mode off Do not repeat more than 5 times to avoid overheating the optics cavity Refer to NOTE 3 for FT3013 copier 52 Fusing Temperatur...

Page 72: ...nge data 0 8 Default 4 Refer to NOTE 6 61 Standard ID Sensor Bias Voltage Setting Factory use Do not change data 0 8 Default 2 62 Standard ID Sensor Grid Voltage Setting Factory use Do not change data 0 8 Default 4 Refer to NOTE 6 63 Open No function 64 Toner Density Level Display Displays the toner density level detected by initial setting SP65 0 4 Data Vsp Vsg 0 12 15 1 0 7 2 8 11 3 16 21 4 22 1...

Page 73: ...pying 188 202 C Default 198 C 188 C to 202 C in 1 C steps Refer to NOTE 3 for FT3013 copier 80 Open No function 83 Toner End Counter Clear Clears the toner end counter SP58 Resets the used toner overflow condition E70 if it is detected 0 No 1 Yes This mode must be performed when the used toner tank is cleaned 86 Energy Saving Ratio Selects energy saving ratio 0 56 1 47 2 37 3 25 The greater the sa...

Page 74: ...Displays the total number of copies fed from the by pass feed table Refer to NOTE 5 101 Paper Tray Copies Displays the total number of copies fed from the paper tray Refer to NOTE 5 102 Open No function 103 Total Copies Displays the total number of copies Refer to NOTE 5 106 DF Originals FT3213 copier only Displays the total number of originals fed from the DF Refer to NOTE 5 110 Misfeeds total Di...

Page 75: ...ers are entered the copier goes automatically into copy mode when the Auto Image Density key is pressed SP mode numbers 5 6 and 55 2 After the following SP mode numbers are entered and the Auto Image Density key is pressed Select the desired input numbers or SP mode data and press the Auto Image Density key SP mode numbers 8 37 41 42 43 44 45 47 48 and 50 NOTE 2 When the data in SP mode 12 is chan...

Page 76: ...the decimal place is displayed in the Copy Counter NOTE 5 FT3013 copier The FT3013 copier displays the SP mode data in the Copy Counter The first two digits are displayed first Press the Lighter key once to display the next two digits and press the Lighter key one more time to display the last two digits six digits in total FT3213 copier The first three digits are displayed in the Magnification In...

Page 77: ... displayed in the Magnification Indicator FT3013 copier Either nothing is displayed or is displayed in the Copy Counter Number Sensor Switch Signal Data 0 FT3213 copier or No display FT3013 copier 1 FT3213 copier or FT3013 copier 1 Registration Sensor Paper not detected HIGH Paper detected LOW 2 Exit Sensor 3 Paper Tray Switch Paper tray opened HIGH Paper tray closed LOW 7 Relay Sensor Paper not d...

Page 78: ... OFF 8 Erase Lamp 9 ID Sensor LED 11 Toner Supply Clutch Main Motor 12 Registration Clutch 13 1st Paper Feed Clutch 15 Relay Roller Clutch 18 Exhaust Blower Motor 19 Optics Cooling Fan FT3213 copier only 20 Exposure Lamp Optics Cooling Fan FT3213 copier only 22 Charge Corona Image Grid with correction Transfer Corona Separation Corona 23 Charge Corona ID Sensor Grid with correction Transfer Corona...

Page 79: ...tput remains LOW de actuated for 6 0 seconds after the lens moves to the home position 29 Lens Home Position Error FT3213 copier only The lens home position sensor s output remains HIGH actuated for 4 0 seconds after the lens leaves the home position 2A 4th 5th Mirror Home Position Error FT3213 copier only The 4th 5th mirror home position sensor s output remains LOW de actuated for 3 0 seconds aft...

Page 80: ...iseconds SP125 Document Feeder NOTE When the E52 E53 or E55 conditions occur for safety reason they cannot be cleared by turning off and on the main switch The following procedure must be performed to clear these service call conditions 1 Turn on the main switch 2 Turn DPS 101 1 on and off 3 Turn the main switch off and on User Code U code Contents 2 Key Counter Not Set U O Scanner not in Home Pos...

Page 81: ...o 2 5 0 1 volts by VR101 TP107 AVSS GND TP110 PSE ID Sensor Voltage Adjust the voltage to 4 0 0 2 volts by VR102 TP111 ETH Optics Thermistor JP101 Key Counter Cut this jumper wire when installing the key counter on the machine DF Main Board NUMBER FUNCTION TP1 Factory use TP2 Factory use TP3 GND TP4 5 volts TP5 GND TP6 24 volts SERVICE TABLES FSM 4 25 A151 A152 ...

Page 82: ... NORMAL FUNCTION JPS101 R Upper Open Factory use JPS101 C Lower Open To clear counters by SP98 or to clear all memory by SP99 DF Main Board SW1 FUNCTION 1 2 3 4 OFF OFF OFF OFF Normal Factory setting Lift Switch must be ON ON OFF OFF ON Free run Insert paper OFF OFF ON ON Solenoid test ON ON OFF ON Motor test ON ON ON ON All indicators ON A151 A152 4 26 FSM ...

Page 83: ...rge corona current VR2 Adjusts standard grid voltage VR3 Adjusts standard development bias voltage TC SC Power Pack NUMBER FUNCTION VRT Adjusts transfer corona current VRD Adjusts separation corona current AC Drive Board NUMBER FUNCTION VR401 Adjusts base exposure lamp voltage Factory use DF Main Board NUMBER FUNCTION VR1 Adjusts original stop position Factory use SERVICE TABLES FSM 4 27 A151 A152...

Page 84: ...ing Pin 4 pcs 1 set A0089502 Grease G 40M 1 52039501 Grease Shinetsu Silicone G 501 1 54429106 Drum Shoe 1 54479104 Shoe Adapter 1 54209507 Digital Multimeter 1 54479078 Heat Resistance Grease MT 78 1 52149500 Test Chart OS A4 10 pcs set 52149501 Test Chart OS A4 100 pcs set A0779505 Drum Shoe Shaft Adapter 1 54429101 Setting Powder 1 A151 A152 4 28 FSM ...

Page 85: ...ower brush Pick off Pawl C C C Dry cloth Quenching Lamp C C C Dry cloth Erase Lamp C C C Dry cloth End Blocks and Casing C C C Water or dry cloth Transfer Guide Plate C C C Dry cloth Corona Wires C R R Water or dry cloth Wire Cleaner I R R Grid Plate C R Blower brush CLEANING UNIT Used Toner Tank C C C Empty used toner Cleaning Seal C C Replace if necessary Cleaning Blade R R Dust with setting pow...

Page 86: ...des C C Suitable solvent Fusing Thermistor I I I Suitable solvent Clean if necessary Fusing Lamp I I I Confirm the temperature by SP52 Replace if necessary OTHERS Exit Roller C C Water Exit Sensor I I Ozone Filter R R Timing Belts I I DOCUMENT FEEDER PM intervals number of originals fed SP106 Transport Belt C C C Belt cleaner Friction Belt C C R Water Pick up Roller C C C Water Feed Roller C C C W...

Page 87: ...shown After cleaning the optics section SP95 SP48 and SP56 MUST be performed and in the order given NOTE 2 Apply setting powder evenly on the surface and edge of the blade as shown to prevent damaging the drum Rev 1 95 SERVICE TABLES FSM 4 31 A151 A152 ...

Page 88: ...harge Wires Dirty charge wires may cause uneven image density They should be cleaned or replaced at regular intervals End Blocks Toner tends to accumulate on the corona end blocks and this can result in poor copy quality or even a high voltage leak Clean end blocks at regular intervals QL If toner accumulates on the QL a dirty background or a repeating negative image may result Clean the QL at reg...

Page 89: ...Inspect the movement as well Fusing Entrance and Exit Guides Toner piling up on the guide plate will cause a dirty background on the copy Clean the guide plate at regular intervals DF Transport Belt A dirty transport belt can leave stains on copies Clean or replace the belt at regular intervals Pick up Roller Separation Roller Separation Belt When dirty these rollers and this belt can leave stains...

Page 90: ... clean sheets of paper to protect it 1 Clean the ID sensor with blower brush 2 Clean the pick off pawl 3 Clean the quenching lamp and erase lamp unit with dry cloth 4 Clean the end blocks casing and transfer guide plate with water or dry cloth 5 Replace the corona wires and wire cleaner 6 Clean the grid plate with blower brush 1 Empty used toner tank 2 Clean the cleaning seal 3 Replace the cleanin...

Page 91: ...5 Clean the entrance and exit guide 1 Replace the pressure roller 1 Clean the exit roller 2 Inspect the exit sensor movement 3 Replace the ozone filter 1 Inspect all the timing belts 1 Reset the VL correction counter by SP95 2 Perform the drum initial setting by SP66 if the drum was replaced 3 Perform the developer initial setting by SP65 4 Adjust the exposure lamp intensity by SP48 5 Adjust the A...

Page 92: ...dicator light when a copy is made Stays LOW CN117 2 The Check Paper Path indicator and J1 indicator light when the main switch is turned on Exit Sensor S5 Stays HIGH CN116 2 The Check Paper Path indicator and J2 indicator light when a copy is made Stays LOW CN116 2 The Check Paper Path indicator and J2 indicator light when the main switch is turned on Relay Sensor S6 Stays HIGH CN117 6 The PE indi...

Page 93: ...the 1st paper tray is closed SHORT The Start key stays green even when the 1st paper tray is open and the J1 indicator lights after the Start key is pressed Exposure Lamp L1 OPEN SC code E11 is displayed Fusing Lamp L2 OPEN SC code E52 is displayed Fusing Thermistor TH1 OPEN SC code E55 is displayed SHORT SC code E53 is displayed Fusing Thermoswitch TS OPEN SC code E52 is displayed Optics Thermofu...

Page 94: ... turned on FU402 250 V 6 3 A ac drive board 220 230 V 240 V machine only Front door safety The copier does not turn on even when the main switch is turned on F1 250 V 2 A DF main board DC power supply for the DF The DF does not turn on even when the main switch is turned on FU101 250 V 2 A Between CN418 on the ac drive board and CN1 of the DF connector 220 230 V 240 V machine only AC power supply ...

Page 95: ...REPLACEMENT AND ADJUSTMENT ...

Page 96: ......

Page 97: ...ing B 1 1 2 Right Cover 1 Open the front cover 2 Open the upper unit C by pushing the release lever D 3 Remove the right cover E 2 screws NOTE The upper unit can lift with force Be sure to support the upper unit with one hand while pushing the release lever with your other hand C E D A B REPLACEMENT AND ADJUSTMENT SM 5 1 A151 A152 ...

Page 98: ...er Left Cover 1 Take out the copy tray B 2 Remove the lower left cover C 2 screws 1 1 5 Upper Rear Cover 1 Remove the upper rear cover D 2 screws 1 1 6 Lower Rear Cover 1 Remove the upper rear cover 2 screws 2 Remove the lower rear cover E 2 screws A B D E C A151 A152 5 2 SM ...

Page 99: ...ws and 2 connectors 6 Remove the operation panel from the upper cover as shown 1 screw and 2 hooks NOTE When reinstalling the operation panel make sure to do the following 1 Pass the operation panel harness C through the hole and connect the 2 connectors before reinstalling the operation panel 2 Insert the rear side of the operation panel into the upper cover and then push in the front side B A C ...

Page 100: ...n the upper unit by pushing the release lever B NOTE The upper unit can lift with force Be sure to support the upper unit with one hand while pushing the release lever with your other hand 3 Remove the inner cover C 5 screws as shown B C A A151 A152 5 4 SM ...

Page 101: ... exposure glass NOTE When reinstalling the exposure glass make sure of the following a The left edge of the glass is flush with the tab to the left of the scale plate and the right glass holder firmly secures the exposure glass b The red mark is positioned on the right hand side facing upwards This side is smoother and generates less static electricity when the DF is used A C B REPLACEMENT AND ADJ...

Page 102: ...4 Move the 1st scanner to the front side Then while holding the scanner press up on the rear spring plate A with a finger and remove the plate with a pair of pliers Leave the front spring plate B in position in the rear side plate cutout 5 Carefully slide the 1st mirror C toward the front of the machine and lift the mirror out of the machine rear side first A C B A151 A152 5 6 SM ...

Page 103: ...lling the mirror that the reflecting surface A is on the upper side as shown 2 Insert the rear spring plate between the mirror and the rear side plate cutout NOTE Make sure that spring plate B is positioned correctly as shown 3 Clean the optics components and perform the necessary SP modes SP95 SP48 and SP56 Rev 1 95 B A REPLACEMENT AND ADJUSTMENT SM 5 7 A151 A152 ...

Page 104: ... the right 4 Remove the front spring plate A of the 2nd mirror B 5 Carefully shift the 2nd mirror toward the front of the machine to remove the rear spring plate C 6 Lift the 2nd mirror out of the machine 7 Remove the pulley bracket D of the exposure lamp harness E 1 screw 8 Remove the 3rd mirror F in the same way as the 2nd mirror B A F E C D A151 A152 5 8 SM ...

Page 105: ... in the front side plate cutout NOTE a Make sure that the notches F in the spring plate are positioned as shown b Do not touch the reflecting surface with bare hands c When reinstalling the pulley bracket G while winding the exposure lamp harness H around the pulley I do not bend or break off the exposure lamp harness d Clean the optics components and perform the necessary SP modes SP95 SP48 and S...

Page 106: ...place the fourth D and fifth E mirrors The procedure for removing the mirrors from their brackets is the same as for the second and third mirrors NOTE a Make sure that the reflecting surface faces the lens b Position the spring plates F as shown c When reinstalling the 4th and 5th mirror assembly make sure that the hooks G and H are properly positioned as shown d Clean the optics components and pe...

Page 107: ... exposure lamp 5 Loosen the screw B in the rear lamp terminal bracket C 6 Take the rear side D of the exposure lamp E off the rear lamp terminal F while pressing the rear terminal 7 Slide the exposure lamp toward the front side and pass the front side of the exposure lamp through the space G between the front scanner clamp H and the front copier frame I while lifting the rear side of the exposure ...

Page 108: ...s properly positioned at the front and rear C terminals b Make sure that the blister D on the lamp is pointing straight up as shown c Return the first scanner to the original position and make sure that the first scanner moves smoothly d Clean the optics components and perform the necessary SP modes SP95 48 and 56 B A D C D A151 A152 5 12 SM ...

Page 109: ...the copier 2 Remove the exposure glass See Exposure Glass Removal 3 Replace the thermofuse A 2 screws NOTE When installing a new thermofuse make sure that the thermofuse B is in contact with the reflector C as shown A C B REPLACEMENT AND ADJUSTMENT SM 5 13 A151 A152 ...

Page 110: ...osen the screw securing the rear first scanner wire clamp A 3 Remove the front first scanner wire clamp B 4 Remove the front and rear wire tightening springs C 5 Loosen the screws securing the front and rear wire fixing plates D 6 Remove the scanner wires E from the left side plate 7 Remove the scanner wires four wires from the drive pulley F 8 Remove the drive pulley 1 E ring C A E E B C F D D A1...

Page 111: ... the light silver wire 2 clockwise one complete turn around the pulley 4 Wind the dark and light silver wires together five and a half times around the pulley Make sure that the dark silver wire is wound six times and the light silver wire is wound six and a half times in total 5 Set the omega clamp C over the wires on the drive pulley D as shown 2 1 A B C D 1 2 3 4 REPLACEMENT AND ADJUSTMENT SM 5...

Page 112: ...f times around the pulley Wind the light silver wire 4 once clockwise around the pulley 9 Slide the omega clamp C down to secure all the wires as shown NOTE a The dark and light silver wires alternate on the pulley with the dark silver wire uppermost b Wires are not wound around the two grooves shown in the illustration rear view D c Wires are wound around all the grooves shown in the illustration...

Page 113: ...osen the wire tension bracket fixing screw B and the wire tension adjusting screw C 14 Loosen the screw securing the front fixing plate D Place wires 2 and 4 on the pulleys as shown 15 Hook the light silver wire 4 onto the front fixing plate and hook the wire tension spring E onto the front fixing plate and the frame projection A B C E D 4 2 REPLACEMENT AND ADJUSTMENT SM 5 17 A151 A152 ...

Page 114: ...n hook one end of tension spring B to the fixing plate and the other end to the frame projection 18 Reinstall and tighten the first scanner clamps C front and rear and remove the four positioning pins and the omega clamp 19 Perform a free run turn DIP switch 101 1 ON to condition the wires 3 1 A B C C A151 A152 5 18 SM ...

Page 115: ...ews C and D securing the wire tension bracket then turn the 2nd scanner positioning screw D clockwise until the rear positioning pin drops and locks in position 4 Tighten the two screws C and D securing the wire tension bracket 5 Make sure the positioning pin B slides in and out smoothly If not repeat step 3 6 Tighten the screws securing the front and rear wire fixing plates E A B E D C REPLACEMEN...

Page 116: ...nt and rear first scanner wire clamps A 2 Insert the front and rear positioning pins B 2 pcs 3 Tighten the wire clamps 22 Reassemble NOTE Always adjust the first scanner wire clamps after adjusting the tension in the second scanner wire A B A151 A152 5 20 SM ...

Page 117: ...aten cover or DF 3 Remove the upper rear cover and the upper cover 4 Remove the 6P connector A from the main board CN 105 and remove the scanner motor harness from the harness clamps 5 Replace the scanner motor B 2 screws C B C A REPLACEMENT AND ADJUSTMENT SM 5 21 A151 A152 ...

Page 118: ...lens drive wire B 4 Remove the upper rear cover 2 screws 5 Open the front cover 6 Open the upper unit by pushing the release lever 7 Disconnect the lens motor 6P connector C 8 Close the upper unit 9 Remove the lens motor bracket D 2 screws and 1 clamp 10 Remove the motor E from the bracket 2 screws and replace the motor 11 Reassemble D E B D A C A151 A152 5 22 SM ...

Page 119: ... half times around the pulley D 3 Unhook the spring and place the bead E at the other end of the wire in slot F on the sensor actuator bracket 4 Reattach the spring to the bracket NOTE Rotate the lens drive pulley and make sure that the lens drive wire moves smoothly B F E C D A REPLACEMENT AND ADJUSTMENT SM 5 23 A151 A152 ...

Page 120: ...cover Right cover 3 Move the 4th 5th mirror assembly A to the left viewed from the front 4 Remove the motor bracket B 2 screws 5 Free the copier main board C 3 locking supports 6 Disconnect the motor 6P connector D located between the main board and the copier frame 7 Separate the 4th 5th mirror motor E from the bracket 2 screws and replace it C D B D E A B A151 A152 5 24 SM ...

Page 121: ...OPMENT UNIT REMOVAL 1 Open the front cover 2 Remove the two screws as shown in the illustration above and take out the development unit A while pulling the left side of the development cover B A B REPLACEMENT AND ADJUSTMENT SM 5 25 A151 A152 ...

Page 122: ...he development unit See Development Unit Removal 2 Remove the toner supply unit A 2 screws NOTE When reinstalling make sure that there is no gap B between the toner supply unit and the development unit See the Illustration B A A151 A152 5 26 SM ...

Page 123: ...e one pack of developer B shake it well and pour it into the development unit while rotating the gears C on both sides to distribute the developer evenly as shown NOTE When installing new developer or manually rotating the development roller always make sure to turn the gears in the direction shown in the above diagram The copier might be damaged if they are turned in the opposite direction 6 Rein...

Page 124: ... A by working a small slotted screwdriver as shown NOTE To install a new inlet seal plate remove the covering from the double sided tape B and affix the inlet seal C to the development unit lower casing Tuck both ends of the seal inside the lower casing as shown A C B A151 A152 5 28 SM ...

Page 125: ...2 Remove the upper rear cover and main board all connectors and 3 locking supports 3 Remove the toner supply clutch bracket A 3 screws 4 Remove the clutch B from the clutch bracket 2 E rings 2 bushing and 1 gear C B C A REPLACEMENT AND ADJUSTMENT SM 5 29 A151 A152 ...

Page 126: ... power pack is replaced 1 Set the multimeter range to dc 1500 V and connect the multimeter leads as shown NOTE Keep the multimeter leads away from the main board 2 Turn on the main switch close the front cover safety switch then turn on the development bias using SP9 38 3 Adjust the development bias voltage to 500 10 V by turning VR3 on the CC Grid Bias power pack A 4 Press the Clear Stop key and ...

Page 127: ...porting your left hand on the cushion A attached under the bottom plate as shown 1 Open the front cover B 2 While holding down the cleaning blade release lever C remove the cleaning unit D 1 screw as shown NOTE When reinstalling make sure that the unit slides properly on the two guide rails E D B A C E REPLACEMENT AND ADJUSTMENT SM 5 31 A151 A152 ...

Page 128: ... Remove the cleaning blade B 1 shoulder screw NOTE a Do not touch the edge of a new cleaning blade as it is damaged easily b Apply setting powder C evenly on the surface and edge of the new cleaning blade c After installing a new cleaning blade make sure it swivels B A C A151 A152 5 32 SM ...

Page 129: ... A 3 Open the toner collection cover B while removing the hooks C NOTE Do not peel off the tape on the toner collection cover 4 Pour the used toner slowly onto the paper sheet so that the toner does not scatter 5 Place the paper sheet with the used toner into a plastic bag NOTE Dispose according to local regulations 6 Reinstall the cleaning unit 7 Perform SP83 to clear the memory counter C B A REP...

Page 130: ...ing surface The lower edge E of the tape must be flush with the edge F of the projection as shown in the illustration 7 Place the new entrance seal on the double sided tape the blue arrow G should point up and be placed on the left side as shown Extend the seal so that both edges H align with the left and right edges I of the tape NOTE a The lower edge J of the entrance seal must be aligned with t...

Page 131: ... cover 4 Open the upper unit by pushing the release lever 5 Remove the manual feed table B 1 screw and 1 shoulder screw 6 Remove the harness cover A 2 screws 7 Remove the relay sensor connector C 8 Remove the relay roller guide plate D as shown 2 screws Rev 4 97 A B D C REPLACEMENT AND ADJUSTMENT FSM 5 35 A151 A152 ...

Page 132: ... screws D 11 Remove three feed roller screws 1 screw each 12 Remove the feed rollers from the shaft E while pushing them up with your hands as shown NOTE When reinstalling the feed rollers make sure that they are positioned on the opposite side of the spring pin F as shown Otherwise the six feed rollers will be positioned incorrectly A E C C B F D A151 A152 5 36 FSM ...

Page 133: ... the release lever 5 Remove the lower rear cover 2 screws 6 Remove the DC power supply unit A 4 screws and all connectors 7 Remove three clutch connectors B 8 Remove the rear side plate C 4 screws 1 clamp D and 1 connector E 9 Remove the paper tray switch F from the rear side plate A B F D D C E REPLACEMENT AND ADJUSTMENT FSM 5 37 A151 A152 ...

Page 134: ...ront cover 3 Open the upper unit by pushing the release lever 4 Remove the harness cover A 2 screws 5 Remove the by pass feed table B 1 screw and 1 shoulder screw 6 Remove the relay sensor connector C 7 Remove the relay roller guide plate D as shown 2 screws Rev 4 97 A B D C A151 A152 5 38 FSM ...

Page 135: ...sor A from the guide plate B as shown 9 Remove the registration sensor bracket C 1 screw and 1 connector D 10 Remove the registration sensor E from the bracket as shown A B C E D REPLACEMENT AND ADJUSTMENT FSM 5 39 A151 A152 ...

Page 136: ...ch 2 Open the front cover 3 Open the upper unit by pushing the release lever 4 Remove the lower rear cover 2 screws 5 Remove the DC power supply unit A 4 screws and all connectors 6 Remove three clutch connectors B 7 Remove the rear side plate C 4 screws 1 clamp and 1 connector A B C A151 A152 5 40 FSM ...

Page 137: ...ghtener D 1 spring E 12 Remove two screws F securing the 1st paper feed unit 13 Remove the E ring G securing the paper feed clutch H 14 Remove the paper feed clutch while slightly lifting the 1st paper feed unit NOTE When reinstalling the clutches make sure that the clutch stoppers lock the clutches A B D E G H C F REPLACEMENT AND ADJUSTMENT FSM 5 41 A151 A152 ...

Page 138: ...upper unit by pushing the release lever B 5 Remove the two screws gold C securing the drum stay and pull out the drum unit D gently along the rail 6 Place the drum unit on a sheet of paper so that the leading edge of the pick off pawls E are pointing upward as shown 7 Remove the front drum holder F 2 screws 8 Remove the drum G by holding the drum unit rail and pulling out and up on the drum knob H...

Page 139: ...um If it is not in contact solid black copies may occur 11 Remove the protective sheet B and apply setting powder E evenly on the drum surface 12 Set the drum unit in the machine 13 Reinstall the other units around the drum unit 14 Reset the drum counter using SP66 NOTE The drum counter must be reset with SP66 whenever an OPC drum is replaced 15 Perform the ID sensor Vsg adjustment using SP54 See ...

Page 140: ...unit by pushing the release lever 4 Remove the drum unit 2 screws NOTE Cover the drum with some sheets of paper to prevent the drum from being exposed to light 6 Disconnect the connector A CN413 from the ac drive board B 3 wire clamps 7 Remove the quenching lamp C from the copier frame as shown NOTE Do not use alcohol to clean the quenching lamp This damages the resin in the covers of the LEDs A B...

Page 141: ...er 2 screws 2 Remove the main board A all connectors and 3 locking supports 3 Remove the erase lamp B 1 screw NOTE Do not use alcohol to clean the erase lamp This damages the resin in the covers of the LEDs A B REPLACEMENT AND ADJUSTMENT FSM 5 45 A151 A152 ...

Page 142: ...s shown b The height adjuster J must be positioned underneath the corona wires c Do not handle the new corona wires with bare hands Oil on the wire may cause uneven charge on the drum d Do not rub the corona wires with rough material sandpaper etc as this will damage the corona wires e When removing the endblock covers be careful not to break off the side hooks f Do not use any solvents to clean t...

Page 143: ...emove the grid plate B as shown NOTE a Oils and chemicals from your hands will deteriorate the grid plate b Do not bend the grid plate This can result in an uneven charge c When installing the charge corona unit make sure that the corona wires are positioned between the cleaner pads See Charge Corona Wire Replacement B A REPLACEMENT AND ADJUSTMENT FSM 5 47 A151 A152 ...

Page 144: ...ft positioning tabs B of the TC SC unit from the left holders C in the transport unit 2 Then take out the TC SC unit 3 as shown 4 Remove the following parts TC SC unit front endblock cover D TC SC unit rear endblock cover E TC SC unit paper guide F NOTE When reinstalling the TC SC unit paper guide verify that all three tabs G are properly latched in place 5 Unhook the springs H from the wires C B ...

Page 145: ...ires with bare hands Oil on the wire may cause an uneven charge condition d Rubbing the corona wires with a rough material sandpaper etc will damage the corona wires e When removing the endblock covers be careful not to break off the side hooks f Do not use any solvents to clean the wires as this will cause uneven charge on the drum g Do not loosen the screws D of the transfer entrance guide E The...

Page 146: ...rt unit then set the left positioning tabs D into the left holders E by pulling the TC SC corona unit towards the registration roller side b Make sure that the four positioning tabs of the TC SC corona unit fit into the holders in the transport unit as shown c Make sure that six springs F are correctly positioned underneath the TC SC corona unit as shown B C E A F D A151 A152 5 50 FSM ...

Page 147: ...th paper to prevent the drum from being exposed to light 2 Remove the ID sensor holder A 1 screw NOTE Do not lose the spur B on the ID sensor holder 3 Replace the ID sensor board C 4 Reinstall the drum unit 5 Perform the ID sensor Vsg adjustment SP54 and check the copy quality C A B REPLACEMENT AND ADJUSTMENT FSM 5 51 A151 A152 ...

Page 148: ... removing it from the drum unit This prevents the drum from being exposed to light 2 Remove the pick off pawl bracket A 1 screw 3 Remove the spring B then remove the pick off pawl C from the shaft D NOTE When replacing the new pick off pawl make sure that the spring is positioned correctly as shown in the illustration A C B D B A151 A152 5 52 FSM ...

Page 149: ... corona unit See Transfer Separation Corona Wire Replacement 5 Remove the harness cover C 2 screws 6 Remove 2 screws 1 grounding screw D 1 screw E 7 Lift the transport unit F by removing the front G and rear H hooks and remove the 4P connector I from the transfer separation T S power pack J Then take out the transport unit B A C D F H I J G E REPLACEMENT AND ADJUSTMENT FSM 5 53 A151 A152 ...

Page 150: ...r D hooks are positioned correctly as shown b When reinstalling the transport unit make sure that the relay harness E does not catch in the transport unit and is positioned correctly as shown 9 Adjust the transfer and separation corona currents See Transfer Corona Current Adjustment and Separation Corona Current Adjustment B A D E C A151 A152 5 54 FSM ...

Page 151: ... with paper separation toner transfer or image density CAUTION Make sure that SP9 is cleared before you change the range on the digital multimeter If not the multimeter may be damaged High voltage is applied to the corona wires Be careful Preparation 1 Turn off the main switch and remove the following parts Upper Inner Cover Development Unit Cleaning Unit Charge Corona Unit TC SC Corona Unit Drum ...

Page 152: ... to the drum holder 7 Attach the drum shaft D and drum shoe E to the drum unit as shown NOTE Be careful not to injure your hand on the edge of the pick off pawls 8 Reinstall the drum unit with the shaft rear end F positioned as shown in the illustration Pass the harness G down into the development unit opening 9 Secure the drum unit 2 screws 10 Connect the negative harness lead to the copier frame...

Page 153: ... the charge corona wires as shown 4 Reinstall the charge corona unit on the drum unit 5 Select the dc 200 µA range on the digital multimeter C 6 Turn on the main switch and close the front cover safety switch 7 Turn on the charge corona using SP9 2 8 Note the reading Wait at least 30 seconds for the current to stabilize 9 Press the Clear Stop key to turn off the charge corona then move the drum sh...

Page 154: ...measurement 1 Turn off the main switch 2 Disconnect the charge corona terminal A from the CC Grid Bias power pack B 3 Select the dc 2mA range on the digital multimeter 4 Connect the multimeter leads as shown then measure the charge corona current NOTE Keep the multimeter leads away from the main board 5 Turn on the main switch close the front cover safety switch and turn on the charge corona using...

Page 155: ...k is replaced 1 Set the multimeter range to dc 1500 V and connect the multimeter leads as shown NOTE Keep the multimeter leads away from the main board 2 Turn on the main switch close the front cover safety switch and turn on the grid voltage using SP9 48 3 Adjust the grid voltage to 880 10 V by turning VR2 on the CC Grid Bias power pack A 4 Press the Clear Stop key and turn off the main switch A ...

Page 156: ...ction plate B is aligned with the transfer corona wire as shown 2 Remove the seal C from the transport unit 3 Select the dc 200 µA range on the digital multimeter 4 Turn on the main switch close the front cover safety switch and turn on the transfer corona using SP9 5 5 Adjust the transfer corona current to dc 31 0 0 5 µA using VRT on the TC SC power pack D 6 Press the Clear Stop key and turn off ...

Page 157: ...a wire as shown NOTE Make sure that the drum shoe does not touch the pick off pawls 2 Remove the seal C from the transport unit 3 Select the ac 200 µA range on the digital multimeter 4 Turn on the main switch close the front cover safety switch and turn on the separation corona using SP9 6 5 Adjust the separation corona current to ac 49 1 0 µA using VRD on the TC SC power pack D 6 Press the Clear ...

Page 158: ...7 FUSING 7 1 EXIT UNIT REMOVAL 1 Remove the copy tray 2 Loosen the screw A in the rear holder B 3 Slide the rear holder toward the rear side and remove the exit unit C A B C A151 A152 5 62 FSM ...

Page 159: ...Cleaning unit 5 Hold down the top of the upper unit and open the upper unit by pushing the release lever 6 Remove the inner cover and pull out the drum unit 2 screws NOTE Cover the drum with some sheets of paper to prevent the drum from being exposed to light 7 Close the upper unit 8 Remove the exit unit See Exit Unit Removal 9 Remove the two screws B securing the fusing unit 10 Remove the front a...

Page 160: ...e upper unit stops at the 90 position as shown 12 Free the four fusing harnesses and remove the unit A as shown 2 screws NOTE Make sure the 3P connector harness B is free from the notch C in the frame before removing the fusing unit A C B A151 A152 5 64 FSM ...

Page 161: ...ng pins B and the positioning screw C fit through the two notches D and the hole E in the fusing frame 2 When closing the upper unit make sure that the torsion bars F are positioned on the front G and rear H brackets as shown A E C B D B G F F H REPLACEMENT AND ADJUSTMENT FSM 5 65 A151 A152 ...

Page 162: ...over A 1 screw 4 Remove the thermoswitch bracket B 1 screw 5 Disconnect the connector C of the fusing lamp from the thermoswitch D 6 Remove the thermistor E 1 screw 7 Remove the front F and rear G support brackets of the fusing lamp 1 screw each 8 Pull the fusing lamp H out of the front end of the hot roller H A G E B C F D A151 A152 5 66 FSM ...

Page 163: ...s H I 1 gear J 1 bearing K 14 Install the new hot roller NOTE a Peel off 3 cm 1 inch from both ends of the protective sheet on the new hot roller before installing it b Before reinstalling the pressure springs remove the rest of the protective sheet c Before reinstalling the pressure springs refer to the Fusing Pressure Adjustment Section D C A F E B K H J I REPLACEMENT AND ADJUSTMENT FSM 5 67 A15...

Page 164: ... guide B 3 Turn the entrance guide clockwise as shown 4 Remove the pick off pawl securing bracket C 2 screws 5 Remove the pressure roller D 6 Remove the bearings E and E rings F from the pressure roller NOTE Before installing the pressure springs refer to the Fusing Pressure Adjustment Section F E E F C D A B A151 A152 5 68 FSM ...

Page 165: ...ear cover 2 screws 7 Remove both front and rear fusing lamp support brackets D 1 screw each 8 Disconnect the fusing lamp connector from the ac drive board and pull the fusing lamp E out of the front end of the hot roller NOTE a Do not touch the fusing lamp with bare hands b Slide the new fusing lamp into the hot roller through the opening at the front of the roller c Make sure that the fusing lamp...

Page 166: ...ng cover A 1 screw 4 Remove the thermoswitch bracket B 1 screw 5 Disconnect the two thermoswitch connectors C 6 Remove the thermoswitch D from the bracket 2 screws NOTE When installing the thermoswitch bracket B make sure that the projection E on the thermoswitch bracket enters into the hole F on the fusing unit frame G C A C B D E F G B A151 A152 5 70 FSM ...

Page 167: ...ower supply cord 2 Remove the drum unit See Drum Replacement 3 Remove the fusing cover A 1 screw 4 Remove the upper rear cover 2 screws 5 Disconnect the thermistor connector B 2 harness clamps 6 Remove the thermistor C 1 screw B A C REPLACEMENT AND ADJUSTMENT FSM 5 71 A151 A152 ...

Page 168: ...Remove the ac drive board bracket with the ac drive board 2 screws and all ac harness connectors 9 Remove the 2 relay gears C on the fusing unit 1E ring each 10 Adjust the fusing pressure spring position as follows Fusing pressure adjustment combinations Spring position setting a Factory setting b Weaker c Stronger The fusing pressure can be set at three different levels Adjust the pressure spring...

Page 169: ...ted from the customer the overall image density can be changed by changing the toner density Normally this should be kept at the normal position factory setting The grid voltage and charge corona current are carefully adjusted at the factory Any adjustment out of the adjustment standard will result in overtoning toner scattering dirty background or light image density problems The grid voltage and...

Page 170: ... and separation and casings Casings Water Wires Dry Cloth 4 QL Erase Lamp Dry cloth 3 Clear the VL correction by using SP95 NOTE Always perform SP95 after cleaning the optics components 4 Place the OS A4 test chart on the exposure glass and make a full size copy at manual image density level 4 center NOTE Make sure that the value of SP37 is set to 0 standard value 5 Confirm that level 2 E0 2 of th...

Page 171: ...a wire height to correct for uneven image density on the copy If the following adjustment does not clear the problem adjust the wire height using the drum shoe See Charge Corona Current Adjustment 1 Perform the light intensity adjustment SP48 and the ADS adjustment SP56 2 Place the OS A4 test chart on the exposure glass and make a copy 3 If the side to side variations of the gray scales are not wi...

Page 172: ...s the bias voltage while the image area on the drum is being developed Data SP37 0 1 2 3 4 Bias Voltage V V0 V0 40 V0 20 V0 20 V0 40 Image Density Normal Darkest Darker Lighter Lightest NOTE V0 is the standard voltage applied to the development roller 1 Make a copy after adjusting the light intensity 2 If the image is blurred Decrease the bias voltage by one step and readjust the light intensity I...

Page 173: ...pply mode does not function Purpose To switch the toner supply system from Detect mode to Fixed mode How to Adjust SP30 How it works Turns on the toner supply clutch every copy cycle by selecting 1 in SP30 8 6 TONER SUPPLY RATIO SELECTION When The factory setting for the toner supply amount is not appropriate for the type of original in use Purpose To adjust the toner supply amount Adjustment Stan...

Page 174: ... correctly Adjustment Standard Vsg 4 0 0 2 volts How to Adjust SP54 How it works Changes the light intensity of the ID sensor LED The Vsg voltage is displayed on the operation panel 1 Turn off the main switch and clean the following parts Item No Section Method 1 ID sensor Blower brush 2 QL Erase Lamp Dry cloth 2 Reinstall all the parts 3 Check Vsg using SP54 Adjust Vsg by turning VR102 main board...

Page 175: ... Reference Voltage 2 5 0 1 volts How to Adjust SP56 How it works Changes the main board ADS output voltage The voltage reading is displayed on the operation panel 1 Place five sheets of A3 11 x 17 paper on the exposure glass 2 Select SP56 and press the Start key 3 If the voltage is not within the adjustment standard adjust it by turning VR101 on the main board REPLACEMENT AND ADJUSTMENT FSM 5 79 A...

Page 176: ...e two screws and move the lens position FT3213 copier SP44 0 2 step 51 steps How it works Changes the lens home position FT3013 copier 1 Place a 150 mm scale parallel to the left scale on the exposure glass 2 Make three copies to check the horizontal magnification 3 Confirm that the scanner wire clamps are positioned correctly using the scanner positioning pins See Scanner Wire Installation 4 Remo...

Page 177: ...gnification 8 10 VERTICAL MAGNIFICATION ADJUSTMENT When The vertical magnification is not within the adjustment standard Purpose To maintain proper vertical magnification Adjustment Standard Less than 1 0 difference between original and copy How to Adjust SP43 0 2 step 16 steps How it works Changes the scanner speed compensation 1 Place a 150 mm scale perpendicular to the left scale on the exposur...

Page 178: ...justs the 4th 5th mirror assembly home position changing the distance between the original and the drum surface FT3013 copier 1 Make three copies with the test chart to check the focus 2 Turn off the main switch and remove the exposure glass See Exposure Glass Removal 3 Remove the lens cover A 2 screws 4 Loosen a screw B and move the 4th 5th mirror assembly to adjust the focus FT3213 copier 1 Make...

Page 179: ...e glass 2 Adjust the leading edge erase margin using SP41 Make three copies and check the erase margin 8 13 REGISTRATION ADJUSTMENT When Registration is not within the adjustment standard Purpose To maintain proper registration Adjustment Standard 0 2 mm 0 0 08 How to Adjust SP42 0 4 mm step 16 steps How it works Changes the registration roller start timing 1 Place a 150 mm scale perpendicular to ...

Page 180: ...er tray adjust the side fence position in the paper tray b When side to side registration is out of the adjustment standard for both the paper tray and the by pass feed table adjust the lens position Check the adjustment by making a copy from the by pass feed table Then make a copy from the paper tray and adjust the side fence position in the paper tray if necessary Side Fence Adjustment Paper Tra...

Page 181: ...ide fences 8 Remove the registration adjustment plate D 2 screws and set it in the desired position NOTE When reinstalling the pinion gear A the lines E on the gear must fit the lines F of the rack gears G C E G F F G B D A REPLACEMENT AND ADJUSTMENT FSM 5 85 A151 A152 ...

Page 182: ...h and remove the exposure glass See Exposure Glass Removal 2 Remove the lens cover 2 screws and lens housing cover FT3213 copier only A 2 screws 3 Loosen two screws B and shift the lens C to adjust the side to side registration A C B A151 A152 5 86 FSM ...

Page 183: ...ges the 4th 5th mirror height CAUTION Never perform this adjustment until you have positively verified that the source of the skewing is optical and not in the paper path 1 Turn off the main switch and remove the exposure glass See Exposure Glass Removal 2 Adjust the 4th 5th mirror height by turning the screw A Refer to the arrows in the illustration A REPLACEMENT AND ADJUSTMENT FSM 5 87 A151 A152...

Page 184: ...ver 2 Remove the cleaning unit See Cleaning Unit Removal 3 Hold down the top of the upper unit and open the upper unit by pushing the release lever 4 Pinch down at the top of the filter at both ends and remove the ozone filter A as shown A A151 A152 5 88 FSM ...

Page 185: ...d hold the Clear Stop key until a dot appears in the top left corner of the copy counter c Release the Clear Stop key and again press the Clear Stop key d Press the Lighter key 6 Perform SP 12 using the following sequence SP Mode Number Procedure 12 Conversion from 220 230V to 240V Enter 12 using the numeral keys Then press the Auto Image Density key Change the setting from 0 to 1 using the numera...

Page 186: ...tion 1 Turn off the main switch 2 Remove the upper rear cover 2 screws 3 Remove the exposure glass See Exposure Glass Removal 4 Install the optics heater A in the optics cavity as shown 2 screws 5 Wire the heater harness B and connect the connector C as shown A B C A151 A152 5 90 FSM ...

Page 187: ...nit A toward the registration roller side 1 and release the left positioning tabs B of the TC SC corona unit from the holders C of the transport unit 2 Then take out the TC SC corona unit 3 4 Remove the harness cover D 2 screws 5 Install the anti condensation heater E 2 screws and connect the heater connector F C B A F D E REPLACEMENT AND ADJUSTMENT FSM 5 91 A151 A152 ...

Page 188: ...3 Hold down the top of the upper unit and open the upper unit A by pushing the release lever 4 Locate the pre transfer lamp opening B below the main board C and gently insert the PTL D as shown 5 Connect the 2P connector of the PTL to CN111 on the main board 1 harness clamp E A C B D E A151 A152 5 92 FSM ...

Page 189: ... A install the fan so that air flows into the optics cavity 2 screws 3 Locate the 2P connector B under the front scanner guide rail and connect it to the fan harness as shown 4 Reinstall all the parts and turn on the machine 5 Access SP91 and confirm that 1 fan mode is selected If not enter 1 and exit the SP mode B A REPLACEMENT AND ADJUSTMENT FSM 5 93 A151 A152 ...

Page 190: ... is turned off and the power supply cord is unplugged 2 Remove the platen cover or DF 3 Open the front cover 4 Remove the following covers and units Development Unit Upper rear cover Upper left A 5 Remove the front and rear upper unit stoppers B 1 screw B A151 A152 5 94 FSM ...

Page 191: ...lows Factory Setting Strongest Setting Remore screw C on both sides Loosen screw A on both sides Shift the adjusting bracket to ward the torsion spring Tighten screws on both sides in positions B and A Front Rear A Factory Setting Torsion Spring Strongest Setting B A B C C Factory Setting Torsion Spring Strongest Setting B C A A B C Screw REPLACEMENT AND ADJUSTMENT FSM 5 95 A151 A152 ...

Page 192: ...e the bracket 180 and install it using holes A and C Factory Setting Weak Setting Remove the adjusting bracket 2 screws on each side Rotate the bracket 180 and install it using holes B and A Front A B C C B A Screw Rear C B A A C B Screw C B A A B C Screw C B A A B C Screw A151 A152 5 96 FSM ...

Page 193: ...TROUBLESHOOTING ...

Page 194: ......

Page 195: ... power pack transfer failure Poor contact of the power pack lead wires Poor contact of the transfer corona wire Leak in the insulator or endblocks 3 The development roller does not rotate Broken drive gear 4 The development roller is not properly grounded 5 Poor drum sensitivity The drum was exposed to fluorescent light or direct sunlight for a long period of time The drum was exposed to ammonia g...

Page 196: ...ive parts Are the charge and transfer corona wires broken No Yes Replace the corona wires Is leakage occurring in the endblocks or receptacles No Yes Replace the defective parts Are the development drive gears worn or broken No Yes Replace the drive gears Does the drum rotate properly Yes No Check drum drive mechanisms such as the drum drive belt and the drum pulleys Good No Good Reinstall them in...

Page 197: ...to LOW replace the CC Grid Bias power pack CN117 13 Transfer trigger line 1 If the signal stays HIGH after the Start key is pressed replace the main board 2 If the transfer corona does not turn on even if the signal changes to LOW replace the TC SC power pack If there is no problem with the signal lines replace the drum if the sensitivity does not recover even when the drum is not exposed to light...

Page 198: ...ses 1 Dirty optics 2 Toner scattering High toner density The inlet seal of the development unit is stripped off The doctor gap is too wide 3 The exposure lamp is not bright enough This may be caused by deterioration of the exposure lamp or low lamp voltage 4 In ADS mode reflected light from the original is too high 5 The ADS optical fiber is cut or bent 6 The development bias is grounded A151 A152...

Page 199: ...on No Yes Replace the exposure lamp Is the signal at CN119 4 LOW after the Start key is pressed No bias voltage is applied to the development roller No Yes Replace CC Grid Bias power pack Replace the main board Is the cleaning blade worn No Yes Replace the cleaning blade Are the erase lamp and or quenching lamp dirty No Yes Clean the erase lamp quenching lamp as required If toner scattering occurs...

Page 200: ... the ADS voltage is not within 0 1 volts of the standard voltage 2 5 V readjust the ADS voltage If the signal at CN101 5 stays HIGH check the harness and sensor and replace defective parts If the signal at CN101 4 stays LOW replace the main board A151 A152 6 6 FSM ...

Page 201: ...cs section dirty No Yes Clean the optics and perform the necessary SP modes in order SP95 48 and 56 Adjust the exposure adjustment plates on the 1st scanner See Side to side Exposure Adjustment Is the erase lamp or quenching lamp dirty No Yes Clean the erase lamp or quenching lamp Are the corona wires or grid plate dirty No Yes Clean the corona wires grid plate and casings Adjust the charge corona...

Page 202: ...n copy is made No Yes Check and clean the optics section After cleaning the optics perform the necessary SP modes in order SP95 48 and 56 Press the blade release lever down two or three times to clean the edge of the cleaning blade If black bands still appear go to the next step Is the edge of the cleaning blade deformed No Yes Replace the cleaning blade If the inlet seal on the development unit i...

Page 203: ... necessary SP modes in order SP95 48 and 56 Is the edge of the cleaning blade scratched No Yes Replace the cleaning blade Is the hot roller scratched No Yes Check whether black lines appear on the copy by stopping the copy paper in the transport section If no black lines appear replace the hot roller Check whether the drum is scratched or toner is built up on the drum If toner is built up on the d...

Page 204: ...med inlet seal on the development unit Action Are the charge corona wires or grid plate dirty No Yes Clean the charge corona wires or grid plate Is the inlet seal damp or deformed No Yes Clean the inlet seal with a dry cloth If the problem is not corrected replace the inlet seal plate and the seal as a set Is the grid plate deformed No Yes Replace the grid plate Replace the charge corona wire A151...

Page 205: ...xt step Make a copy and stop the machine when the paper reaches the transport section Do white lines appear on the copy No Yes Replace the drum if it is scratched Replace the hot roller if it is scratched NOTE If the drum is scratched find out what caused the scratches on the drum and correct the problem Paper misfeed Incorrect positioning of the pick off pawls Foreign substances on the cleaning b...

Page 206: ... If black lines appear at 91 mm intervals the cause is a scratched hot roller 3 Toner adheres to the drum surface Due to insufficient cleaning foreign matter may accumulate on the blade causing toner to stick to the drum surface when the drum stops Action Is the drum scratched No Yes Replace the drum Is the hot roller scratched No Yes Replace the hot roller If toner adheres to the drum surface cle...

Page 207: ...s such as the drum drive belt and drum pulleys No Good Reinstall them correctly or replace the defective parts Is the scanner wire tension correct Yes No Readjust the scanner wire tension Does the voltage of CN105 2 through 5 on the main board stay at 24 volts when the Start key is pressed 24 volts Not 24 volts Replace the scanner motor or check the scanner drive Replace the main board TROUBLE SHO...

Page 208: ...te CC G B power pack defective Main board defective Action Is there good electrical contact between the charge corona casing and the grid plate Yes No Repair the poor contact and replace any parts if needed Check the voltage at CN119 1 on the main board 0 volts Not 0 volts Replace the main board Replace the CC G B power pack A151 A152 6 14 FSM ...

Page 209: ...rs 2 Mirrors are in the wrong position 3 The stubs of the 4th 5th mirror assembly are off the rails Action Is each mirror positioned correctly on its scanner and on the 4th 5th mirror assembly Yes No Reposition the mirror correctly If the spring plates are defective replace them Are the stubs of the 4th 5th mirror assembly off the rails No Yes Put the mirror assembly stubs back on the rails Readju...

Page 210: ...bias voltage modules is too low 6 The charge corona current is too low 7 The ID sensor grid voltage is too low Action Has an ID sensor abnormal condition occurred No Yes See the ID Sensor Abnormal Condition section Clean the optics section and the area around the drum Clear the VL cor rection with SP95 Make a few sky shot copies and then readjust the light intensity and the ADS voltage Does the to...

Page 211: ...s the charge corona current correct Yes No Readjust the charge corona current Is the grid voltage correct Yes No Readjust the grid voltage Check SP33 If the setting is greater than 2 reset the value to 0 TROUBLE SHOOTING FSM 6 17 A151 A152 ...

Page 212: ...toner supply mode 4 The main board is defective 5 The ID sensor voltage is too high 6 The charge corona current is too high 7 The ID sensor grid voltage is too high Action Does an ID sensor abnormal condition occur No Yes See the ID Sensor Abnormal Condition section Does the toner supply clutch rotate Yes No Check the voltage at CN110 1 on the main board 24 volts 0 volts Replace the toner supply c...

Page 213: ...ent correct No Yes Readjust the charge corona current Go to A Is the grid voltage correct Yes No Readjust the grid voltage A Clean the optics section and around the drum Turn on DIP switches 101 1 and 101 2 on the main board Enter SP55 Repeat the free run until Vsp becomes lower than 0 103 Vsg Perform the necessary SP modes in order SP95 48 56 and 54 TROUBLE SHOOTING FSM 6 19 A151 A152 ...

Page 214: ...density is too high 2 The inlet seal on the development unit is out of position 3 The developer has deteriorated Action Is the toner density too high No Yes See section 1 12 Toner Density Too High Is the inlet seal deformed No Yes Replace the inlet seal plate Replace the developer A151 A152 6 20 FSM ...

Page 215: ...The fusing temperature is too low 3 The thermistor is malfunctioning Action Adjust the position of the pressure springs to increase the fusing pressure No good Increase the fusing temperature using SP79 No good Check the thermistor If the thermistor is malfunctioning replace it TROUBLE SHOOTING FSM 6 21 A151 A152 ...

Page 216: ...or is de fective Replace the defective sensor If no sensors are defective replace the main board Action 2 Misfeed during copy cycle If the PE indicator turns on after the Start key is pressed check whether the paper tray has run out of paper or not No Yes Load the paper into the paper tray Set Jam Detection OFF mode SP6 to on and make a copy to see whether a misfeed occurs Misfeed No misfeed Check...

Page 217: ... corona output 3 Damp paper 4 Extremely high humidity and temperature Action 1 Clean around the Transfer Separation unit 2 Check the corona current and adjust if necessary 3 Instruct the customer to keep paper in a dry place 4 The pre transfer lamp PTL is available as an optional service part Install the PTL by following the procedure described in section 5 TROUBLE SHOOTING FSM 6 23 A151 A152 ...

Page 218: ...the transport belt Action Is the red mark on the exposure glass positioned on the right hand side fac ing upwards Yes No Reinstall the exposure glass so that the red mark is positioned on the right hand side facing upwards Clean the exposure glass surface with alcohol or water Pour a small amount of silicone oil on the exposure glass and wipe the exposure glass with a dry cloth to reduce the frict...

Page 219: ...ive board Defective main board Defective dc harness CN114 on the main board or CN401 on the ac drive board is not correctly connected Action Turn the main switch off and on Exposure lamp off Yes No Check the voltage at CN114 3 on the main board 24 volts Less than 20 volts Replace the main board Replace the ac drive board Check that CN114 on the main board and CN401 on the ac drive board are correc...

Page 220: ...pen Replace the exposure lamp Is the thermofuse open No Open Replace the thermofuse Is the exposure lamp harness defective No Yes Replace the exposure lamp harness Replace the main board A151 A152 6 26 FSM ...

Page 221: ...le Causes Defective ac drive board Defective main board Action Turn the main switch off and on Check the voltage at CN114 3 on the main board after the Start key is pressed Less 24 volts than 20 volts Replace the main board Check the voltage at CN114 2 on the main board More than Less than 0 5 volt 0 5 volt Replace the ac drive board Replace the main board TROUBLE SHOOTING FSM 6 27 A151 A152 ...

Page 222: ...upply board is not correctly connected Action Turn the main switch off and on Check that CN107 on the main board and CN202 on the dc power supply board are correctly connected Correct Incorrect Connect CN107 and CN202 Check the voltage at CN202 2 on the dc power supply board 0 6 volt 0 volts Replace the dc power supply board Check the voltage at CN107 1 on the main board 0 6 volt 0 volts Replace t...

Page 223: ...ower supply board open blown fuse Action Turn the main switch off and on Check the position of the 1st scanner sensor actuator Actuated De actuated Does the scanner motor rotate when the main switch is turned on No Yes Correct the scanner drive wire position Check the voltage at CN106 2 on the main board 24 volts 0 volts Check FU202 on the dc power supply board Good No Good Replace FU202 Replace t...

Page 224: ...e main switch is turned on 17 volts 24 volts Replace the main board Replace the scanner motor Is there 5 volts at CN103 11 on the main board when the scanner H P sensor is actuated Yes No Replace the scanner H P sensor Replace the main board A151 A152 6 30 FSM ...

Page 225: ...onnected FU202 on the dc power supply board open blown fuse Action Turn the main switch off and on actuator position Check the position of the 1st scanner sensor actuator Deactuated Actuated Does the scanner motor rotate when the main switch is turned on No Yes Correct the scanner drive wire position Check the voltage at CN106 2 on the main board 24 volts 0 volts Check FU202 on the dc power supply...

Page 226: ...N103 and CN105 on the main board are correctly connected Correct Incorrect Connect CN103 and CN105 Is there 0 volts at CN103 11 on the main board when the scanner H P sensor is deactuated No Yes Replace the main hoard Check if the dc harness signal line for the sensor is defective No Defective Replace the dc harness Replace the scanner H P sensor A151 A152 6 32 FSM ...

Page 227: ...urn the main switch off and on Check the sensor actuator position on the lens assembly Actuated De actuated Does the lens motor rotate when the main switch is turned on No Yes Check the lens drive mechanism and repair or replace the defective parts Check the voltage at CN103 1 and 6 on the main board 24 volts 0 volts Replace the main board Check the voltage at CN103 2 to 5 on the main board when t...

Page 228: ...Is there 5 volts at CN103 8 on the main board when the lens H P sensor is actuated Yes No Replace the lens H P sensor Replace the main board A151 A152 6 34 FSM ...

Page 229: ...s not correctly connected Action Turn the main switch off and on Check the position of the lens assembly sensor actuator De actuated Actuated Does the lens motor rotate when the main switch is turned on No Yes Check the lens drive mechanism and repair or replace the defective parts Check the voltage at CN103 1 and 6 on the main board 24 volts 0 volts Replace the main board Check the voltage at CN1...

Page 230: ...nect CN103 Is there 0 volts at CN103 8 on the main board when the lens H P sensor is deactuaed No Yes Replace the main board Check whether the dc harness signal line for the sensor is defective No Defective Replace the dc harness Replace the lens H P sensor A151 A152 6 36 FSM ...

Page 231: ...sm Action Turn the main switch off and on Check the sensor actuator position on the 4th 5th mirror assembly Actuated De actuated Does the 4th 5th mirror motor rotate when the main switch is turned on No Yes Check the 4th 5th mirror drive mechanism and repair or replace the defective parts Check the voltage at CN104 1 and 6 on the main board 24 volts 0 volts Replace the main board Check the voltage...

Page 232: ...Is there 5 volts at CN102 2 on the main board when the 4th 5th mirror H P sensor is actuated Yes No Replace the 4th 5th mirror H P sensor Replace the main board A151 A152 6 38 FSM ...

Page 233: ...the main board is not correctly connected Action Turn the main switch off and on Check the sensor actuator position on the 4th 5th mirror assembly De actuated Actuated Does the 4th 5th mirror motor rotate when the main switch is turned on No Yes Check the 4th 5th mirror drive mechanism and repair or replace the defective parts Check the voltage at CN104 1 and 6 on the main board 24 volts 0 volts R...

Page 234: ...CN102 and CN104 Is there 0 volts at CN102 2 on the main board when the 4th 5th mirror H P sensor is deactuated No Yes Replace the main board Check whether the dc harness signal line for the sensor is defective No Yes Replace the dc harness Replace the 4th 5th mirror H P sensor A151 A152 6 40 FSM ...

Page 235: ... not correctly connected Action Check the resistance between CN113 pin 1 and pin 2 Approx 8 KΩ Ω Open Replace the thermistor Check the voltage at CN113 2 on the main board 5 volts 0 volts Replace the main board Check the voltage at CN113 1 on the main board About 1 8 volts 0 volts Replace the thermistor Replace the main board TROUBLE SHOOTING FSM 6 41 A151 A152 ...

Page 236: ...ness CN114 on the main board or CN401 on the ac drive board is not correctly connected Action Clear the service call condition Does the fusing lamp turn on when the main switch is turned on Yes No Check that CN114 on the main board and CN401 on the ac drive board are correctly connected Correct Incorrect Connect CN114 and CN401 Is the fusing lamp open No Yes Replace the fusing lamp Is the thermosw...

Page 237: ...ain board Check the voltage at CN114 8 on the main board 24 volts 0 volts Replace the main board Does the thermistor properly contact the hot roller Yes No Correctly position the thermistor Does the voltage at TP102 on the main board increase after the main switch is turned on Yes No Replace the thermistor Replace the ac drive board TROUBLE SHOOTING FSM 6 43 A151 A152 ...

Page 238: ...Fusing harness shorted Action Clear the service call condition Check the voltage at TP107 on the main board More than Less than 3 45 volts 3 45 volts Replace the main board Has the thermistor shorted No Yes Replace the thermistor Check the voltage at CN114 4 on the main board 24 volts 0 volts Replace the main board Replace the ac drive board or check the fusing harness A151 A152 6 44 FSM ...

Page 239: ...ac drive board Fusing lamp open Thermoswitch open Defective ac harness Action Is the thermistor open No Yes Replace the thermistor Clear the service call condition Does the fusing lamp turn on No Yes Replace the main board Is the fusing lamp open No Yes Replace the fusing lamp Is the thermoswitch open No Yes Replace the thermoswitch Is the ac harness defective No Yes Replace the ac harness No TROU...

Page 240: ...ts 24 volts Replace the main board Check the voltage at CN114 4 on the main board 0 volts 24 volts Replace the main board Check the voltage at CN114 8 on the main board 24 volts 0 volts Replace the main board Replace the ac drive board A151 A152 6 46 FSM ...

Page 241: ...tch off and on and place some originals on the original table Does the original start feeding when the Start key is pressed No Yes Does the DF motor rotate No Yes Check the feed in or transport drive mechanism and repair or replace the defective parts Check that CN117 on the DF main board is correctly connected Correct Incorrect Connect CN117 Turn on DIP switches 1 3 and 4 on the DF main board and...

Page 242: ...correctly connected Correct Incorrect Connect CN113 and CN121 Turn on DIP switches 1 3 and 4 on the DF main board and turn on the lift switch Check the voltage at CN113 on the DF main board 1 5 volts 0 volts Replace the pulse generator sensor Replace the DF main board A151 A152 6 48 FSM ...

Page 243: ...witch is turned on Possible Causes The optical fiber cable is not correctly connected to the DF main board or the DF interface board CN2 on the DF interface board or CN120 on the main board is not correctly connected Defective optics fiber cable Defective main board Defective DF main board Defective DF interface board Defective dc harness between CN2 and CN120 TROUBLE SHOOTING FSM 6 49 A151 A152 ...

Page 244: ...sg voltage displayed on the operation panel with SP55 5 00 0 00 Vsp 2 5 volts Vsg 2 5 volts Is the copy image too light No Yes Refer to the Light Copy section Is the ID sensor circuit open No Yes Replace the ID sensor and adjust Vsg to 4 0 0 2 volts Replace the main board and adjust Vsg to 4 0 0 2 volts Is the ID sensor surface dirty with toner No Yes Clean the ID sensor with a blower brush and if...

Page 245: ...olts when checking TP110 on the main board with SP 54 No Yes Readjust Vsg to 4 0 0 2 volts Check whether the ID sensor has a short No short Short Replace the ID sensor Replace the main board TROUBLE SHOOTING FSM 6 51 A151 A152 ...

Page 246: ...C Starting temp 41 C 45 C 43 C Possible Case Optics thermistor short circuit Excessive continuous copy jobs Action Is the optics thermistor short circuited No Yes Replace the thermistor Check if the customer has run excessive continuous copy jobs Yes No Replace the main board Notify the customer that the machine may stop when excessive continuous copy jobs are performed NOTE The same optics coolin...

Page 247: ...r light when a copy is made Stays LOW CN117 2 The Check Paper Path indicator and J1 indicator light when the main switch is turned on Exit Sensor S5 Stays HIGH CN116 2 The Check Paper Path indicator and J2 indicator light when a copy is made Stays LOW CN116 2 The Check Paper Path indicator and J2 indicator light when the main switch is turned on Relay Sensor S6 Stays HIGH CN117 6 The PE indicator ...

Page 248: ...en when the 1st paper tray is closed SHORT The Start key stays green even when the 1st paper tray is open and the J1 indicator lights after the Start key is pressed Exposure Lamp L1 OPEN SC code E11 is displayed Fusing Lamp L2 OPEN SC code E52 is displayed Fusing Thermistor TH1 OPEN SC code E55 is displayed SHORT SC code E53 is displayed Fusing Thermoswitch TS OPEN SC code E52 is displayed Optics ...

Page 249: ...n FU402 250 V 6 3 A ac drive board 220 230 V 240 V machine only Front door safety The copier does not turn on even when the main switch is turned on F1 250 V 2 A DF main board DC power supply for the DF The DF does not turn on even when the main switch is turned on FU101 250 V 2 A Between CN418 on the ac drive board and CN1 of the DF connector 220 230 V 240 V machine only AC power supply for the D...

Page 250: ......

Page 251: ...DOCUMENT FEEDER A296 ...

Page 252: ......

Page 253: ...nsumption 35 W Dimensions W x D x H 590 x 443 x 100 mm 23 3 x 17 5 x 4 0 Weight Approximately 7 kg 15 5 lb Specifications are subject to change without notice The document feeder DF40 can only be installed on the FT3213 Only DF40 document feeders from S N A296 4 05 0001 have the necessary accessory parts for installation on to the FT3213 These accessory parts include 1 ADF Interface Bracket Assy P...

Page 254: ...r 7 Transport Belt 8 Transport Belt Roller 9 Feed Roller 10 Relay Roller 1 2 3 4 6 5 7 8 9 10 1 Pick up Solenoid 2 Registration Sensor 3 Original Set Sensor 4 Feed Clutch 5 Pulse Generator Sensor 6 DF Motor 7 Insert Original Indicator 8 Original Misfeed Indicator 9 Lift Switch 10 DF Main Board 11 DF Transformer 12 DF Interface Board 1 2 3 4 5 6 7 8 9 10 11 A151 A152 7 2 FSM ...

Page 255: ...upplies timing pulse to the DF main board 5 S2 Original Set Sensor Informs the copier CPU that originals have been placed and causes the Insert Original indicator to go out 3 S3 Registration Sensor Sets original stop timing and checks for original misfeeds 2 Printed Circuit Board PCB1 DF Main Board Controls all DF functions 10 PCB2 DF Interface Board Interfaces between the copier main board and th...

Page 256: ...ve the strips of tape from the DF CAUTION This procedure step 4 must be done only in 240 volt areas 4 Perform the conversion from 220 230 V to 240 V as follows 1 Remove the main board cover C 2 screws 2 Disconnect the connector for 220 230 V D Black Wire from the ac harness connector E and reconnect the connector for 240 V F White Wire to the ac harness connector 3 Reinstall the cover Rev 1 95 A B...

Page 257: ...screw and 1 clamp 9 Locate the 4P connector F and connect it to the ADF interface board G then fix the ADF interface unit H to the copier 1 screw while securing the harnesses through the wire clamp NOTE Use the screw that secured the ADF bracket I 10 Plug in the connector J 3P Black to CN418 on the ac drive board K E I D H A B C G F K J H DOCUMENT FEEDER A296 FSM 7 5 A151 A152 ...

Page 258: ... Plug the optics fiber cable A into the DF and the copier 13 Plug the power supply cord B of the DF into the outlet in the copier rear cover 14 Attach the voltage reference decal C 15 Install the original table D D A C B A151 A152 7 6 FSM ...

Page 259: ... screw B 20 Install the upper unit stand C 1 longer stepped screw D 21 Attach the magnet E 22 Attach the decal F 23 Close the upper unit and the front cover 24 Check the operation of the DF 25 Instruct key operators how to use the upper unit stand A B C D A E F DOCUMENT FEEDER A296 FSM 7 7 A151 A152 ...

Page 260: ...pply cord and 1 optics harness 4 Remove the grip guide C 2 screws 5 Remove the transformer cover D 3 screws DF motor cover E 4 screws and main board cover F 2 screws 6 Remove the transport belt assembly G 5 screws and 1 drive belt H NOTE When installing the transport belt assembly make sure that the positioning pin I fits into the DF frame A B E F D I G C H A151 A152 7 8 FSM ...

Page 261: ...1 snap ring and 1 bushing 8 Pull out the transport belt B NOTE After reinstalling the transport belt make sure that the bushings of the transport rollers set correctly and the transport belt turns smoothly B A DOCUMENT FEEDER A296 FSM 7 9 A151 A152 ...

Page 262: ...ment 3 Remove the left hinge bracket A 4 screws and 1 connector 4 Disconnect five connectors from the main board B CN111 CN113 CN115 CN116 and CN117 5 Remove the feed in unit C 5 screws NOTE When reinstalling the feed in unit the harness must be positioned underneath the right hinge bracket C A B A151 A152 7 10 FSM ...

Page 263: ...ff the main switch 2 Remove the feed in unit See Feed in Unit Removal 3 Remove the DF motor A 2 screws and 1 timing belt B 4 Remove the pick up roller C 2 E rings and 1 bushing from the shaft D B A C D DOCUMENT FEEDER A296 FSM 7 11 A151 A152 ...

Page 264: ...bushing D NOTE Be careful not to lose the spring pin 4 Slide the feed roller shaft E towards the front and remove the feed clutch F 1 E ring and 1 connector 5 Take out the feed roller shaft 1 spacer and 1 bushing from the rear side 6 Remove the feed roller G from the shaft 3 idler rollers H 7 E rings and 1 spring pin I NOTE Be careful not to lose the spring pin H E G F D A C B I A151 A152 7 12 FSM...

Page 265: ...emove the friction belt assembly A 1 screw 3 Remove the friction belt B 2 springs 1 pin NOTE When installing the friction belt assembly make sure the feed roller C is set in the correct position See the illustration C A B DOCUMENT FEEDER A296 FSM 7 13 A151 A152 ...

Page 266: ...between the plunger and the solenoid 5 Turn the solenoid lever D clockwise until the plunger touches the thickness gauge Just at this point tighten two screws 6 Make sure that the pick up lever E is touching the pick up roller F when the plunger is pushed If not repeat steps 3 to 5 7 Reassemble the DF 8 Turn on the main switch and check the original feed in operation F E A C B D A151 A152 7 14 FSM...

Page 267: ...03 copier is based on the A152 copier Only the differences from the A151 A152 copier are described in the following pages Refer to the A151 A152 copier s service manual for additional information A model cross reference table can be found in the specifications section of this manual ...

Page 268: ......

Page 269: ...r grid voltage and the drum wear correction factor 3 Drum Residual Voltage VR Detection and Correction The drum residual voltage VR detection and drum residual voltage VR correction have been eliminated 4 Drum Wear Correction The drum wear correction has been eliminated Optics 1 Optics Cooling Fan The optics cooling fan is installed for both A202 and A203 copiers The optics cooling fan is installe...

Page 270: ...n sensor only during the first copy after some particular actions are performed Installation 1 Document Feeder A662 The document feeder can be installed on the FT4015 A219 as well When installing make sure to use the correct interface unit bracket SP Modes 1 Display of SP Mode Number Which are Above 100 The manual ID indicator is used instead of 1 in the copy counter is displayed instead of 1 in t...

Page 271: ...R Ratio Display Vr correction not performed 68 VR Forced Detection Vr correction not performed 79 Fusing Temperature Adjustment Same as A202 A203 SP49 87 PM Interval Setting Eliminated due to small capacity of EEPROM 88 PM Counter Display Eliminated due to small capacity of EEPROM 89 PM Counter Clear Eliminated due to small capacity of EEPROM 91 Optics Cooling Fan Operation A151 copier only No nee...

Page 272: ...SS Y A4 A2031426 OPERATION PANEL ASS Y A4 A2021427 OPERATION PANEL ASS Y A2031427 OPERATION PANEL ASS Y A2021433 OPERATION PANEL ASS Y LT A2031433 OPERATION PANEL ASS Y LT A2031735 FAN MOTOR 24 V 3 6 W A2034131 THERMOSTAT 170 C 120 V 15 A A2025103 MAIN CONTROL BOARD A2035103 MAIN CONTROL BOARD A2025106 MAIN CONTROL BOARD A2035106 MAIN CONTROL BOARD A2025108 IC UVEPROM 512 k x 8 150NS A2035108 IC U...

Page 273: ...NIQUE PARTS FOR A202 A203 SERIES Compared with the A151 A152 series PM Parts Parts Number Description A4971170 Friction Belt Electrical Parts Parts Number Description A6625010 Main Control Board SM 5 A202 A203 ...

Page 274: ......

Page 275: ...achine the upper unit becomes lighter If the upper unit is released under this condition it tends to open very abruptly The service engineer might be injured if he is leaning over the machine at this time Also the machine might move due to the shock of the upper unit opening abruptly To avoid possible injury or machine damage hold the upper unit firmly when opening the unloaded upper unit 7 Due to...

Page 276: ... on the specific models SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Do not incinerate the toner cartridge or the used toner Toner dust may ignite suddenly when exposed to open flame 2 Dispose of used toner developer and organic photoconductors according to local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance with local regulations A202 A203 ii FSM ...

Page 277: ...A202 A203 SERVICE MANUAL ...

Page 278: ......

Page 279: ... lengthwise Copy Paper Weight Paper tray feed 64 to 90 g m2 17 to 24 lb Bypass feed 52 to 105 g m2 14 to 28 lb Reproduction Ratios 2 Enlargement and 3 Reduction A203 copier only A4 Version Letter Version Enlargement 141 122 129 121 Full size 100 100 Reduction 93 82 71 93 74 65 Zoom From 61 to 141 in 1 steps A203 copier only Copying Speed 13 copies minute A4 81 2 x 11 lengthwise 10 copies minute B4...

Page 280: ...z 15 A for North America 220 V 240 V 50 Hz 8 A for Europe 220 V 50 Hz 8 A for Middle East 220 V 60 Hz 8 A for Saudi Arabia 220 V 50 Hz 8 A for Asia Refer to the serial number plate rating plate to determine the power source required by the machine Power Consumption Copier Only With DF Maximum 1 4 kVA 1 5 kVA Warm up 620 VA average 640 VA average Copy cycle 810 VA average 860 VA average Ready 160 V...

Page 281: ... only 43 kg 94 8 lb With DF 50 kg 110 2 lb Optional Equipment Sales items Document feeder A203 copier only Key counter Optional Equipment Service items Drum anti condensation heater Optics anti condensation heater Pre transfer lamp Specifications are subject to change without notice Cross Reference Table Product Code Ricoh Model Name Savin Gestetner Nashau Tec A202 FT3513 9113 2713 2713S A203 FT37...

Page 282: ...L correction factor Reproduction ratio correction factor A203 copier only Image bias voltage adjustment factor SP37 Note Base bias voltage at manual ID level 7 can be adjusted with SP50 Toner Density Detection Standard ID sensor grid voltage 460 V Same as image density control Depends on ID sensor bias setting SP33 Note For the initial 499 copies bias voltage is increased by 20 volts ID sensor pat...

Page 283: ...t 7 Pressure Roller 8 Fusing Unit 9 Hot Roller 10 Exit Rollers 11 Copy Tray 12 Hot Roller Strippers 13 Exhaust Blower Motor 14 3rd Mirror 15 2nd Mirror 16 1st Mirror 17 Ozone Filter 18 Used Toner Tank 19 Cleaning Blade 20 Quenching Lamp 21 Charge Corona Unit 22 Lens 23 6th Mirror 24 Erase Lamp 25 Drum 26 4th Mirror 27 5th Mirror 28 Optics Cooling Fan Motor in A202 A203 29 Toner Supply Unit 30 Deve...

Page 284: ... Motor 18 Optics Thermofuse 19 Auto Image Density Sensor 20 Fusing Thermistor 21 Exposure Lamp 22 Lens Motor A203 copier only 23 Scanner Home Position Sensor 24 Optics Thermistor 25 Lens Home Position Sensor A203 copier only 26 Power Pack CC Grid Bias 27 AC Drive Board 28 N A 29 Scanner Motor 30 4th 5th Mirror Home Position Sensor A203 copier only 31 4th 5th Mirror Motor A203 copier only 32 Main M...

Page 285: ...in this copier Symbol Name Function Index No MSC1 Toner Supply Clutch Drives the toner supply roller 35 TR Fusing Triac 115 V only Switches the fusing lamp on and off 28 The following part has been changed Symbol Name Function Index No L3 Quenching Lamp Receives dc power from the main board the lamp in the A151 A152 received ac power from the ac drive board 11 A202 A203 Copier ELECTRICAL COMPONENT...

Page 286: ...mg Main Motor Gear Timing Belt Drive Gear Timing Belt Pulley Timing Belt G1 G23 BP1 TB1 Relay Gear G10 Timing Belt Drive Gear G11 Timing Belt Pulley BP5 Timing Belt TB3 Timing Belt Pulley BP6 Development Gear G12 Relay Gear G2 Relay Gear G8 Relay Gear G9 Fusing Drive Gear G3 Hot Roller Gear G4 Relay Gear G7 Relay Gear G6 Exit Roller Gear G5 Development Section Development Unit Cleaning Unit Fusing...

Page 287: ...r G25 Drum Drive Gear G26 Timing Belt Pulley BP3 BP2 Timing Belt Pulley Paper Feed Section Timing Belt Drive Gear G24 A B Relay Gear G20 Relay Roller CL Gear G17 Relay Roller CL 2nd Relay Roller Gear G16 2nd Relay Rollers 1st Relay Rollers Gear G19 1st Relay Rollers Toner Supply Motor Gear G13 Toner Supply Gear Toner Supply Unit G14 A203V505 wmf A202 A203 Copier DRIVE LAYOUT SM 8 9 A202 A203 ...

Page 288: ...ts 24 volts and a zero cross signal all of which are supplied to the main board Fusing Lamp Exposure Lamp Main Motor Document Feeder Option Main SW Power Relay RA401 Main Motor Relay RA402 Exposure Lamp Drive Circuit Fusing Lamp Drive Circuit Main Board Solenoids Clutches Power Packs Lens Motor A203 copier only 4th 5th Mirror Motor A203 copier only Optics Cooling Fan Motor A202 and A203 copier Exh...

Page 289: ...to the fusing lamp drive circuit and the exposure lamp drive circuit on the ac drive board The fusing lamp drive circuit receives a trigger signal from the main board and the fusing lamp lights The exposure lamp does not turn on until the main board sends a trigger pulse to the exposure lamp drive circuit When the key is pressed the main board energizes the main motor relay RA402 Then the main mot...

Page 290: ... is set at the factory and the setting is different for each machine The setting of SP60 is printed on the SP mode data sheet located inside the inner cover of the machine 8 2 2 Auto Image Density Level Factor SP34 Auto image density level Data SP34 Change of grid voltage volts Normal 0 0 Darker 1 40 Lighter 2 0 Factory setting The grid voltage and the exposure lamp voltage are constant regardless...

Page 291: ...d voltage Grid voltage Standard ID sensor grid voltage 460 volts SP62 4 The standard ID sensor grid voltage SP62 is set at the factory and the setting is different for each machine The setting of SP62 is printed on the SP mode data sheet located inside the inner cover of the machine A202 A203 Copier DRUM CHARGE SM 8 13 A202 A203 ...

Page 292: ...e sensor registers the home position This occurs when the actuator plate C enters the lens home position sensor A small vibration can be observed when the lens moves through the home position from the enlargement side to the reduction side because the lens is going in the wrong direction to register the home position The lens overshoots the home position by four pulses before going back to registe...

Page 293: ...or level 4 Vo of manual image density mode A value from 100 to 170 can be selected 9 3 EXPOSURE LAMP CONTROL CIRCUIT The circuit is different from the A151 and A152 copiers at the indicated locations dashed circles T401 A203D503 wmf A203D504 wmf A202 A203 Copier OPTICS SM 8 15 A202 A203 ...

Page 294: ...elopment bias is applied whenever the drum is rotating The bias trigger pulse applied to CN1 4 is a pulse width modulated signal PWM signal The width of the pulses controls the voltage level of the development roller As the width of the trigger pulses increase the voltage to the development roller also increases The power pack is equipped with its own feedback circuit to monitor the development bi...

Page 295: ...Y 11 1 ID Sensor Control Circuit This circuit is different from the A151 and A152 copiers at the dashed circle indicated location Rev 5 30 97 24V VA 5V VB A203D509 wmf A202 A203 Copier TONER DENSITY DETECTION AND TONER SUPPLY SM 8 17 A202 A203 ...

Page 296: ...s turn past the pin hole plate E the toner drops into the development unit through the pin holes The toner agitator F mechanism which is contained in the toner cartridge prevents toner from clumping The toner agitator gear G turns whenever the toner supply motor energizes Rotation passes through the toner cartridge casing to the agitator junction H C B A A203D508 wmf F D H G E A207D507 img TONER D...

Page 297: ...egistration sensor Paper length mm Paper size 364 B4 356 10 x 14 330 81 2 x 13 297 A4R 279 81 2 x 11 267 8 x 101 2 257 B5R 254 8 x 10 216 51 2 x 81 2 210 A5R Since the CPU does not have the paper length in memory for the first copy cycle the CPU controls the machine for the maximum paper size of B4 257 mm x 364 mm From the second copy cycle on the CPU controls the machine for the correct paper siz...

Page 298: ...ate If the hot roller temperature reaches 240 C the resistance of the thermistor becomes too low At that time pin 1 of IC120 becomes HIGH turning off Q101 and stopping PC402 At the same time E53 lights on the operation panel and the power relay RA401 turns off Even if the thermistor overheat protection fails a thermoswitch installed in series with the fusing lamp prevents the fusing unit from exce...

Page 299: ...cal English 3 Symbol Explanation Decal Multi language 26 machines 4 Installation Procedure Multi language 10 15 22 26 50 machines 5 Operation Instructions English 10 15 17 22 26 28 29 machines 6 Operation Instructions Chinese 19 50 machines 7 NECR English 17 machines 8 NECR Multi language 19 27 28 29 machines 9 Copy Tray 10 User Survey Card 17 machines A202 A203 Copier INSTALLATION SM 8 21 A202 A2...

Page 300: ...INSTALLATION PROCEDURE 1 Remove the strips of tape from the copier as shown 2 Pull out the paper tray A then remove the foam block B and tapes Close the paper tray A203I500 wmf B A A203I501 wmf INSTALLATION A202 A203 8 22 SM ...

Page 301: ...G by pressing the release lever H Gently remove the shipping spacers I from the transfer separation corona unit J Remove the strip of tape K and close the upper unit CAUTION Be sure to place and hold your left hand on top of the upper unit while pushing the release lever to the right with your right hand The upper unit will raise with force and holding the upper unit will prevent it from lifting t...

Page 302: ...he two center screws on the toner supply unit 9 Shake one pack of developer E well and pour it into the development unit while rotating the gears F on both sides to distribute the developer evenly as shown in the illustration 10 Reinstall the toner supply unit on the development unit NOTE Make sure that there is no gap G between the toner supply unit and the development unit See the illustration A...

Page 303: ...k to be sure the toner agitator in the cartridge turns freely and slide it into the machine while pulling off the seal B Then complete installing the cartridge as shown 13 Close the front cover B A A203I509 img A A203I510 img A202 A203 Copier INSTALLATION SM 8 25 A202 A203 ...

Page 304: ...e top left corner of the copy counter c Release the key and again press the key again d Press the key then input 65 with the number keys 3 Operate SP 65 as follows SP Mode Number Procedure 65 Developer Initial Setting Enter 65 using the number keys and press the key 50 will be displayed in the copy counter Press the key to start the initial setting It takes about 5 minutes Continue to next page Re...

Page 305: ... 16 Install the copy tray C 17 Load paper into the paper tray D as explained in the instructions written on the paper tray 18 Change the paper size plate E to display the correct paper size 19 Check the machine operation and copy quality A A203I511 wmf A B A203I512 wmf C A203I513 wmf D E A203I514 wmf A202 A203 Copier INSTALLATION SM 8 27 A202 A203 ...

Page 306: ...w M4 x 12 2 3 Stud Screw M3 2 4 Installation Procedure English 1 5 NECR Multi language 1 6 Interface Unit for A219 copier 1 7 Accessory Kit for A203 copier 1 Interface Unit Bracket 1 Stud Screw M4 2 Harness Clamp 1 Upper Unit Stand 1 Stepped Screw Short 1 Stepped Screw Long 1 Magnet 1 Operation Decal 1 Screw Driver 1 INSTALLATION A202 A203 8 28 SM ...

Page 307: ...m the DF CAUTION The next step step 4 must be done only for 240 volt areas 4 Perform the conversion from 220 230 V to 240 V as follows 1 Remove the main board cover C 2 screws 2 Disconnect the connector for 220 230 V D Black Wire from the ac harness connector E and connect the connector for 240 V F White Wire to the ac harness connector 3 Reinstall the cover A B A662I517 wmf F 230 240 V D 220 230 ...

Page 308: ... the ADF bracket E 1 screw and 1 clamp 9 Remove the interface harness F 3 screws and the interface board with 2 locking supports G from the A219 interface unit bracket H 10 Attach the interface board and the interface harness to the A203 interface unit bracket I 3 screws A B C A662I506 img E D A662I507 img I H F G A662I513 wmf INSTALLATION A202 A203 8 30 SM ...

Page 309: ...per rear cover 14 Plug the optics fiber cable F into the DF and the copier as shown 15 Plug the DF power supply cord G into the outlet in the rear of the copier as shown 16 Open the front cover 17 Lift up the upper unit CAUTION Be sure to place and hold your left hand on top of the upper unit while pushing the release lever to the right with your right hand The upper unit will raise with force and...

Page 310: ...it stand C 1 longer stepped screw D 21 Attach the magnet E as shown 22 Attach the decal F as shown 23 Close the upper unit and the front cover 24 Instruct key operators how to use the upper unit stand A B C D A A662I510 img E A662I511 img F A662I512 img INSTALLATION A202 A203 8 32 SM ...

Page 311: ...t remove the DF grip D 2 screws then adjust the position of the magnet catch E so that the rubber pad is in contact with the top of the operation panel cover 26 Turn on the main switch and check the operation of the DF C E A662I514 img D E A662I515 img A202 A203 Copier INSTALLATION SM 8 33 A202 A203 ...

Page 312: ...een accessed 5 Enter the desired SP mode number using the number keys The SP mode numbers are given in the Service Program Mode Table NOTE 1 is displayed in the Manual ID indicator as shown below instead of 1 in the Copy Counter when SP mode numbers over 100 are entered The maximum number is 111 6 Press the key to view the current setting NOTE To enter a different SP mode number press the key 7 To...

Page 313: ...l Service Calls 1 Enter SP mode Refer to the SP mode access procedure on page 8 34 2 Enter 98 with the number keys then press the key to view the current setting 3 Enter 1 using the number keys then press the and keys at the same time NOTE The Manual Image Density indicator blinks back and forth when the above procedure is completed 4 Turn off the main switch A202 A203 Copier SERVICE PROGRAM MODE ...

Page 314: ...bove procedure is completed Be certain to complete the following 4 Clean the used toner tank since the toner end counter has been cleared See Used Toner Removal in the A151 A152 Service Manual CAUTION Skipping this step will cause the used toner overflow condition not to be detected properly 5 Load new developer See Developer Replacement in the A151 A152 Service Manual NOTE Since the software coun...

Page 315: ... ADS Voltage Adjustment 5 SP54 Vsg Adjustment 6 SP42 Registration Adjustment 7 SP41 Leading Edge Erase Margin Adjustment 8 SP43 Vertical Magnification Adjustment 9 SP44 Horizontal Magnification Adjustment A203 copier only 10 SP47 Focus Adjustment A203 copier only 10 Turn off the main switch A202 A203 Copier SERVICE PROGRAM MODE SM 8 37 A202 A203 ...

Page 316: ...stop the free run Press the key in Ready mode to turn off this mode Use this mode for the scanner movement check To save toner remove the development unit Refer to NOTE 1 6 Misfeed Detection Off Copies are made without misfeed detection Press the key to make a copy Press the key in Ready mode to turn off this mode Use this mode to check whether a paper misfeed was caused by a sensor malfunction Th...

Page 317: ...g the main switch off on the fusing temperature control mode is changed 30 Toner Supply Mode Selects the toner supply system 0 Detect Mode 1 Fixed Mode See SP31 SP32 for the toner supply amount 31 Toner Supply Ratio Detect Mode Determines how much toner is supplied in detect mode 0 15 1 7 2 30 3 60 32 Toner Supply Ratio Fixed Mode Determines how much toner is supplied in fixed mode 0 7 0 1 3 5 2 1...

Page 318: ... 8 4 Refer to NOTE 1 45 Registration Buckle Paper Feed Adjust the amount of paper buckle in the registration area 0 15 Default 8 0 4 mm per step 3 2 mm to 2 8 mm Refer to NOTE 1 47 Focus Adjustment A203 copier only Adjusts the 4th 5th mirror position to correct focus 0 100 Default 40 This mode must be done after horizontal and vertical magnification adjustment SP43 and 44 Refer to NOTE 1 48 Light ...

Page 319: ...key The Vsp and Vsg voltage readings are updated every 10 or 5 copies depending on the SP35 selection In free run mode the Vsg and Vsp readings are updated every copy cycle Refer to NOTE 1 and refer to NOTE 3 for the A202 copier 56 ADS Reference Voltage Display and Adjustment Displays the ADS reference voltage Before performing this mode clean the optics and perform SP95 and SP48 After adjusting t...

Page 320: ...alled The copier automatically returns to normal mode after initial setting is completed 66 Drum Initial Setting Used to condition the new drum 0 No 1 Yes Initial setting must be done when a new drum is installed The Drum Rotation Time SP57 and the OPC counter SP69 are cleared 69 OPC Counter Shows the total number of copies made with the drum installed in the machine Refer to NOTE 4 71 VL Correcti...

Page 321: ...ore performing this mode clean the optics parts After performing this mode perform SP48 and SP56 96 Toner End Force Cancel The Toner End condition is canceled forcibly By pressing the key to enter this SP mode the toner end condition is canceled 97 Service Call E5 Reset Resets a service call E5 condition Turn the main switch off and on to check if the service call condition is reset 0 Default 1 Re...

Page 322: ...Calls Displays the total number of times the service call indicator has turned on NOTE 1 1 After the following SP mode numbers are entered the copier goes automatically into copy mode when the Auto Image key is pressed SP mode numbers 5 6 7 52 56 59 and 65 2 After the following SP mode numbers are entered and the key is pressed select the desired input numbers or SP mode settings and press the key...

Page 323: ...Copy Counter The first two digits are displayed first Press the key once to display the next two digits and press the key one more time to display the last two digits six digits in total A203 copier The first three digits are displayed in the Magnification Indicator Press and hold the key to display the last three digits six digits in total NOTE 5 The setting will vary depending on the factory set...

Page 324: ... How to check sensor switch inputs for the A203 copier 1 Enter SP mode 8 as outlined in the Service Program Mode Access Procedure on page 8 34 then press the Auto Image key 2 Enter the desired number from the following table 3 Press the key again 4 Enter the number of copies and press the key Either 0 or 1 is displayed in the Magnification Indicator No Sensor Switch Signal Display Condition 0 1 1 ...

Page 325: ...ing Lamp 2 Charge Corona Standard Image Grid 3 Charge Corona Standard ID Sensor Grid 5 Transfer Corona 6 Separation Corona 8 Erase Lamp 10 ID Sensor LED 11 Toner Supply Motor 12 Registration Clutch 13 Paper Feed Clutch 15 Relay Roller Clutch 17 Machine Shut Off 18 Exhaust Blower Motor 19 Optics Cooling Fan 20 Exposure Lamp Optics Cooling Fan 21 Total Counter 30 37 Development Bias Voltage in 40 vo...

Page 326: ...h VR102 TP106 EXPO Exposure Lamp Voltage JP101 Key Counter Cut this jumper wire when installing the key counter on the machine 16 2 DIP SWITCHES AND JUMPER SWITCHES The following jumper switches are not included JPS101 R Upper JPS101 C Lower 16 3 VARIABLE RESISTORS CC Grid Bias Power Pack Number Function VRC Adjusts the charge corona current VRG Adjusts the standard grid voltage VRB Adjusts the st...

Page 327: ...on Error The detected frequency is not within 45 65 Hz The fusing lamp stays on for longer than 38 seconds while the main motor is off 21 Scanner Home Position Error The scanner home position sensor s output remains LOW de actuated for 9 seconds after the main switch is turned on 22 Scanner Home Position Error The scanner home position sensor s output remains HIGH actuated for 1 0 second after the...

Page 328: ...Fusing Error The temperature detected by the thermistor does not rise more than 20 C within 12 seconds when the fusing lamp is turned on continuously in the main motor off condition 55 Fusing Thermistor Open The temperature detected by the thermistor does not reach 40 C within 15 seconds after the main switch is turned on 70 Used Toner Overflow The overflow counter reached 80 k copies or the toner...

Page 329: ...Belt C R R Belt cleaner Friction Belt C R R Belt cleaner Pick up Roller C C C Soft cloth dampened with water Feed Roller C C C Soft cloth dampened with water The Transport Belt has been made a PM part The cleaning method has been changed NOTE Clean the Transport Belt and Friction Belt at the copier PM interval A202 A203 Copier PREVENTIVE MAINTENANCE SCHEDULE SM 8 51 A202 A203 ...

Page 330: ...upper rear cover and main control board all connectors and 4 locking supports 3 Remove the toner supply motor bracket A 3 screws 4 Remove toner supply motor gear shaft assy D 2 e clips 5 Remove the motor B from the bracket 2 screws Rev 5 30 97 A B D A203R500 wmf REPLACEMENT AND ADJUSTMENT A202 A203 8 52 SM ...

Page 331: ...Upper Cover Removal procedure 3 Hold down the top of the upper unit and open the upper unit by pushing the release lever 4 Remove the drum unit 2 screws NOTE Cover the drum with some sheets of paper to prevent the drum from being exposed to light 6 Disconnect the connector A CN127 from the main control board B 7 Remove the quenching lamp C from the copier frame as shown NOTE Do not use alcohol to ...

Page 332: ...1 Turn off the main switch 2 Disconnect the charge corona terminal A from the CC Grid Bias power pack B 3 Select the dc 2 mA range on the digital multimeter 4 Connect the multimeter leads as shown then measure the charge corona current NOTE Keep the multimeter leads away from the main board 5 Turn on the main switch close the front cover safety switch and turn on the charge corona using SP9 2 6 Ad...

Page 333: ...ced 1 Set the multimeter range to dc 1 500 V and connect the multimeter leads as shown NOTE Keep the multimeter leads away from the main board 2 Turn on the main switch close the front cover safety switch and turn on the grid voltage using SP9 46 3 Adjust the grid voltage to 760 10 V by turning VRG on the CC Grid Bias power pack A 4 Press the key and turn off the main switch A A203R503 img A202 A2...

Page 334: ...replaced 1 Set the multimeter range to dc 1 500 V and connect the multimeter leads as shown NOTE Keep the multimeter leads away from the main board 2 Turn on the main switch close the front cover safety switch then turn on the development bias using SP9 38 3 Adjust the development bias voltage to 500 10 V by turning VRB on the CC Grid Bias power pack A 4 Press the key and turn off the main switch ...

Page 335: ...the transfer corona wire as shown 2 Remove the seal C from the transport unit 3 Select the dc 200 µA range on the digital multimeter 4 Turn on the main switch close the front cover safety switch and turn on the transfer corona using SP9 5 5 Adjust the transfer corona current to dc 31 0 0 5 µA using VRT on the TC SC power pack D 6 Press the key and turn off the main switch Rev 7 97 A B A203R505 img...

Page 336: ... shown NOTE Make sure that the drum shoe does not touch the pick off pawls 2 Remove the seal C from the transport unit 3 Select the ac 200 µA range on the digital multimeter 4 Turn on the main switch close the front cover safety switch and turn on the separation corona using SP9 6 5 Adjust the separation corona current to ac 49 1 0 µA using VRD on the TC SC power pack D 6 Press the key and turn of...

Page 337: ...DOCUMENT FEEDER A662 ...

Page 338: ......

Page 339: ...tion belt Original Transport One flat belt Copying Speed 13 copies minute A4 lengthwise or 81 2 x 11 lengthwise Power Consumption 45 W Dimensions W x D x H 590 x 443 x 87 5 mm 23 3 x 17 5 x 3 4 Not including the original table Weight Approximately 7 kg 15 5 lb NOTE The A662 DF44 document feeder can only be installed on the A203 copiers Specifications are subject to change without notice PM items f...

Page 340: ...Exit Roller 7 Transport Belt 8 Transport Belt Roller 9 Feed Roller 10 Relay Roller 1 2 3 4 5 6 7 8 9 10 11 A662V501 img 12 A662V502 img 1 Pick up Solenoid 2 Registration Sensor 3 Original Set Sensor 4 Feed Clutch 5 Pulse Generator Sensor 6 DF Motor 7 Insert Original Indicator 8 SADF Indicator 9 Lift Switch 10 DF Main Board 11 DF Transformer 12 DF Interface Board COMPONENT LAYOUT A202 A203 9 2 SM ...

Page 341: ...ulses to the DF main board 5 S2 Original Set Sensor Informs the copier CPU that originals have been placed and causes the Insert Original indicator to go out 3 S3 Registration Sensor Sets original stop timing and checks for original misfeeds 2 Printed Circuit Board PCB1 DF Main Board Controls all DF functions 10 PCB2 DF Interface Board Interfaces between the copier main board and the DF 12 Transfo...

Page 342: ...let ac power through the ac drive board and outputs 25 volts ac to the DF main board Then the dc power supply circuit on the DF main board converts the 25 volts ac input to 24 volts and 5 volts 24 volts is used by the DF motor the pick up solenoid and the feed clutch 5 volts is used by other electrical components A662D500 wmf POWER DISTRIBUTION A202 A203 9 4 SM ...

Page 343: ...noid and feed clutch to feed in the bottom sheet of the original stack onto the exposure glass The pick up solenoid and the feed clutch remain energized until the original s leading edge reaches the registration sensor The DF motor turns off shortly after the original s trailing edge passes the registration sensor Then the DF motor pauses and reverses for a moment to align the edge of the original...

Page 344: ...T The copier CPU and the DF CPU communicate via the interface board using fiber optics The interface board changes the optical signals to electrical signals and vice versa A662D509 wmf INTERFACE CIRCUIT A202 A203 9 6 SM ...

Page 345: ...ensor The DF CPU then sends the original set signal to the copier CPU to inform it that the document feeder will be used When the key is pressed the pick up solenoid B is energized The original stack is then pressed between the pick up lever C and pick up roller D The rotation of the pick up roller advances the bottom original B C A D A662D502 img DOCUMENT FEEDER A662 ORIGINAL FEED SM 9 7 A202 A20...

Page 346: ...r D presses the original stack and the pick up roller E advances the bottom original of the stack The feed roller moves the original past the friction belt because the driving force of the feed roller is greater than the resistance of the friction belt The friction belt prevents multiple feeds because the resistance of the friction belt is greater than the friction between original sheets A B D E ...

Page 347: ... up solenoid and the feed clutch are de energized when the original s leading edge passes through the registration sensor The DF motor remains energized to deliver the original to the exposure glass until a certain number of pulses 10 to 25 pulses after the original s trailing edge passes through the registration sensor Then the DF motor pauses and reverses for 15 pulses to align the edge of the o...

Page 348: ...the transport belt roller B and the exit roller drive belt C When the DF CPU receives the original change signal from the copier CPU the DF motor starts turning The transport belt carries the original to the exit rollers D and the exit rollers complete the original feed out D A B C A662D506 img ORIGINAL FEED A202 A203 9 10 SM ...

Page 349: ...N117 2 This causes the DF motor to start turning in the forward direction Within 10 to 25 pulses after the original s trailing edge passes through the registration sensor the CPU stops sending the ON signal and the Forward signal The DF motor stops turning Then the CPU outputs the ON signal and the reverse signal for 15 pulses Then the driver IC outputs 0 volts to CN117 1 and 24 volts to CN117 2 t...

Page 350: ...ghts the Check Paper Path and Misfeed Location J0 indicators on the operation panel When the main switch is turned on the DF CPU checks the registration sensor output for initial original misfeed During original feed in the DF CPU performs two types of original misfeed detection 1 Whether the registration sensor is actuated within 500 milliseconds after the pick up solenoid and the feed clutch tur...

Page 351: ...oid Test 1 1 0 1 Motor Test 1 1 1 1 All Indicators On NOTE All the functions are executed when the DF is closed 8 2 VARIABLE RESISTORS VR No Function VR1 Adjusts registration 8 3 FUSE Fuse No Rating Blown Fuse Condition F1 F2 A 250 V The DF will not operate DOCUMENT FEEDER A662 SERVICE TABLES SM 9 13 A202 A203 ...

Page 352: ...ess 4 Remove the grip guide C 2 screws 5 Remove the transformer cover D 3 screws DF motor cover E 4 screws and main board cover F 2 screws 6 Remove the transport belt assembly G 5 screws and 1 drive belt H NOTE When installing the transport belt assembly make sure that the positioning pin I fits into the DF frame A B A662R500 img I C G E F D H A662R501 img REPLACEMENT AND ADJUSTMENT A202 A203 9 14...

Page 353: ...ing 8 Pull out the transport belt B NOTE After reinstalling the transport belt make sure that the bushings of the transport rollers are set correctly and the transport belt turns smoothly B A A662R502 img DOCUMENT FEEDER A662 REPLACEMENT AND ADJUSTMENT SM 9 15 A202 A203 ...

Page 354: ...eft hinge bracket A 4 screws and 1 connector 4 Disconnect five connectors from the main board B CN111 CN113 CN115 CN116 and CN117 5 Remove the feed in unit C 5 screws NOTE When reinstalling the feed in unit the harness must be positioned underneath the right hinge bracket C A B A662R503 img REPLACEMENT AND ADJUSTMENT A202 A203 9 16 SM ...

Page 355: ... Remove the feed in unit See Feed in Unit Removal 3 Remove the DF motor A 2 screws and 1 timing belt B 4 Remove the pick up roller C 2 E rings and 1 bushing from the shaft D B A C D A662R504 img DOCUMENT FEEDER A662 REPLACEMENT AND ADJUSTMENT SM 9 17 A202 A203 ...

Page 356: ...reful not to lose the spring pin 4 Slide the feed roller shaft E towards the front and remove the feed clutch F 1 E ring and 1 connector 5 Take out the feed roller shaft 1 spacer and 1 bushing from the rear side 6 Remove the feed roller G from the shaft 3 idler rollers H 7 E rings and 1 spring pin I NOTE Be careful not to lose the spring pin H E G F D A C B I A662R505 img REPLACEMENT AND ADJUSTMEN...

Page 357: ...mbly A 1 screw 3 Remove the friction belt B 2 springs 1 pin NOTE When installing the friction belt assembly make sure the fiction belt roller is set in the correct position See the illustration A662R506 img A B A662R507 img DOCUMENT FEEDER A662 REPLACEMENT AND ADJUSTMENT SM 9 19 A202 A203 ...

Page 358: ... and the solenoid 5 Turn the solenoid lever D clockwise until the plunger touches the thickness gauge Just at this point tighten two screws 6 Make sure that the pick up lever E is touching the pick up roller F when the plunger is pushed If not repeat steps 3 to 5 7 Reassemble the DF 8 Turn on the main switch and check the original feed in operation F E A C B D A662R508 img REPLACEMENT AND ADJUSTME...

Page 359: ...TECHNICAL SERVICE BULLETINS ...

Page 360: ......

Page 361: ...rp 1 While applying downward pressure to the Upper Unit unlatch and raise the Upper Unit 2 Remove the Right Cover A 2 screws 3 Clean the Right Development Stay B with alcohol 4 Peel off the seal from the Plate C and adhere the Plate onto the Right Development Stay 5 Clean the surface of the Plate C with alcohol 6 Peel off the seal from a second Plate D and adhere the Plate D to the first Plate C 7...

Page 362: ...he Torsion Bar Angles will be modified so that the Torsion Spring strength is reduced In addition the new style Torsion Bar Brackets can be adjusted in four 4 increments The strength of the Torsion Sprin gs can be adjusted at installation or by a service representative upon customer demand UNITS AFFECTED All FT3013 3213 copiers manufactured during the month of December 1994 and beyond will have th...

Page 363: ...aise the Upper Unit 2 Remove the Right Cover A 2 screws 3 Clean the Right Development Stay B with alcohol 4 Peel off the seal from the Plate C and adhere the Plate onto the Right Development Stay 5 Clean the surface of the Plate C with alcohol 6 Peel off the seal from a second Plate D and adhere the Plate D to the first Plate C 7 Reassemble the machine ORDERING PROCEDURE Ricoh Corporation will aut...

Page 364: ...hown REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A0771098 A1521198 Torsion Bar Angle Rear 1 3 S 39 4 A0771197 A1521197 Torsion Bar Angle Front 1 39 24 UNITS AFFECTED All FT3013 3213 copiers manufactured after Serial Number A3605030154 and A3615030945 respectively will have the new style Torsion Bar Angles installed during production FIELD SERVICE MANUAL INSERT PAGES The Torsion...

Page 365: ...BJECT FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bull etin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 4 20 Updated Information ...

Page 366: ... your Parts Catalog as follows Part Number Description Parts Catalog Page Item Incorrect A0779501 Drum Anti condensation Heater 115V Option 13 15 18 39 A0779502 Drum Anti condensation Heater 220V Option Correct AX400021 Anti condensation Heater 115V 18W Option 13 15 18 39 AX400022 Anti condensation Heater 220V 18W Option ...

Page 367: ...ERENCE PART NUMBER DESCRIPTION PAGE ITEM A1521367 Decal Symbol Explanation German 59 1 A1521368 Decal Symbol Explanation French 59 1 A1521369 Decal Symbol Explanation Italian 59 1 A1521370 Decal Symbol Explanation Spanish 59 1 A1528601 Operating Instructions German 59 3 A1528602 Operating Instructions French 59 3 A1528603 Operating Instructions Italian 59 3 A1528604 Operating Instructions Spanish ...

Page 368: ...BJECT FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bull etin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 5 60 Updated Information ...

Page 369: ...eplace this item please order the DC Harness A1525360 REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A1525036 Operation Panel Harness 1 0 45 22 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NE...

Page 370: ...N Power the machine OFF and return the scanner to the home position Then power ON the machine to clear the U O condition FIELD SERVICE MANUAL INSERT GENERAL The Field Service Manual page s listed below must be replaced with the page s supplied Each bull etin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 4 24 Updated Information Add User code...

Page 371: ... SP modes have been added to the Field Service Manual Replace page 4 13 and 4 22 of the Field Service Manual with the updated pages provided with this package Mode No Function Settings SP14 Auto off time can be selected 0 30 minutes default 1 15 minutes 2 1 hour 3 1 5 hours 4 2 hours SP9 7 Output Check for the Main Switch the machine will turn OFF The Auto Off time can also be selected by the cust...

Page 372: ...Tech Service Bulletin No 3013 3213 008 Page 2 of 3 Continued ...

Page 373: ...Tech Service Bulletin No 3013 3213 008 Page 3 of 3 ...

Page 374: ...ibed above has been added Two wires have been added to the AC Harness INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be...

Page 375: ...ed to provide an opening for the new Main Switch 5 The AC Harness has been extended to compensate for the change in the position of the main switch The new components added to the main board are as follows 6 The Energy Star decal has been added on the bottom right corner of the front cover Continued Part Number Description 11024201 CN126 14000291 Q110 14020780 D106 16114222 R173 R174 Main Switch B...

Page 376: ...1 1 49 2 A1515105 A1515108 IC512 X 8 150NS D FT3013 1 1 3 49 2 11024201 Connector 2P 1 2 49 104 14000291 Transistor 2SA1020Y 1 2 49 128 14020780 Diode 11ES2 0 2 49 220 16114222 Resistor R173 R174 0 2 48 214 A1525313 A1525314 AC Harness 1 1 1 45 14 A1525324 Harness Main Switch 0 1 45 25 A1521325 A1521340 Left Lower Cover 1 1 7 19 A1526728 Decal Left Cover 0 1 7 20 DENOTES NEW ITEM UNITS AFFECTED Al...

Page 377: ...SE Main Board ROM SOLUTION Install the updated ROM FT3013 A1515108A FT3213 A1525108A UNITS AFFECTED All FT3013 copiers manufactured from A360508XXXX through A360511XXXX and all FT3213 copiers manufactured from A361508XXXX through A361511XXXX will require the upgraded ROM ORDERING PROCEDURE Ricoh Corporation will automatically ship one replacement ROM for each unit shipped based on Ricoh s Equipmen...

Page 378: ...213 Parts Catalogs This informa tion should be incorporated into all existing Parts Catalog documentation REFERENCE INCORRECT PART NO CORRECT PART NO DESCRIPTION QTY PAGE ITEM AA151617 AA150196 Shielding Toner Hopper Left 1 1 27 29 CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY ...

Page 379: ...s This info rmation should be incorporated into all existing Parts Catalog documentation Please correct your Parts Catalog as follows REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM A0774010 A1524010 Fusing Unit Cover 1 1 33 1 CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q OTHER Note This copy intended as master of original for reproduction of additional bulletins q F ...

Page 380: ... incorporated into all existing FT3013 3213 Parts Catalog documentation INCORRECT REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A1522856 Spring Plate 2 17 3 CORRECT REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A1522855 Guide Plate 2 17 3 CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q OTHER Note This copy intended as master of original for reproduction of additional bulletins ...

Page 381: ...ighted by an arrow 8 2 Updated Information 8 17 Updated Information 8 26 Updated Information 8 34 Updated Information 8 36 Updated Information 8 38 8 39 Updated Information 8 41 Updated Information 8 43 8 46 Updated Information 8 48 8 50 Updated Information 8 52 Updated Information 8 57 8 58 Updated Information 9 1 Updated Information CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q...

Page 382: ...ion 1 Part Number Description Correction REFERENCE OLD PART NO NEW PART NO DESCRIPTION PAGE ITEM A2026205 Upper Cover A202 NRG INF 7 16 A2031260 Upper Cover NRG INF 7 16 2 Not Listed REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0777680 Bias Terminal Ass y 1 43 30 09513010W Philips Screw with Flat Washer M3 x 10 2 43 116 Continued CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q ...

Page 383: ...as it is a PM part REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM A0779521 Separation Corona Wire 10 pcs set 1 31 12 4 Add the following to your PM parts index Section Name Part Number Description Qty Page and Index No Transfer Separation Section A202 A203 A0779521 Separation Corona Wire 10 pcs set 1 31 12 ...

Page 384: ...ly Field Countermeasure 1 Set SP 29 to 0 On Off Control Production Countermeasure 1 New Firmware applied during production E version ROM 2 Install F version ROM for the FT3713 Note Do not select the Phase Control Mode unless needed UNITS AFFECTED All FT3513 3713 copiers manufactured after Serial Number A7407900066 A7417900734 will have the new E version ROM installed during production The Serial N...

Page 385: ...mber given will represent a request for 1 ROM FT3513 ROM P N A2025108E or FT3713 ROM P N A2035108F Note The ROM will be available at no charge for 90 days until January 31 1998 Serial Number s 1 6 2 7 3 8 4 9 5 10 All serial number information will be verified before shipment is made NOTE Old ROM s must be returned within five 5 days to Ricoh Corporation Att Tech Service Copier 155 Passaic Avenue ...

Page 386: ...escribed as Feed Mylar 2 Item No 2 Spring Plate AF022078 will now be available as two parts Item No 2 the Roller AF022078 and Item No 3 the Spring Plate A1522856 3 The following Parts Corrections are being issued for all FT3013 3213 3513 3713 Parts Catalogs REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM AF022078 AF022078 Roller 12 2 17 2 A1522856 Spring Plate 2 17 3 A1522855 Feed Myla...

Page 387: ...eased under the 3013 3213 3513 3713 series Because of this oversight they have been renumbered as Date 3013 3213 3513 3713 014 Service Manual Insert 07 29 97 3013 3213 3513 3713 015 Parts Catalog Corrections 07 29 97 3013 3213 3513 3713 016 Software Modifications 11 17 97 These bulletins will not be reissued at this time please renumber the existing bulletins as indicated above ...

Page 388: ...s F MODs MOD MO s EBs FEBs FEBs MODs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs Ds FEBs ODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MO MODs F MODs FEBs MODs FEBs MOD MODs FE MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs FEBs MODs...

Page 389: ...lowing parts updates are being issued for all A202 and A203 Parts Catalogs REFERENCE PART NO DESCRIPTION QTY PAGE ITEM A0771665 Front Terminal Holder 1 11 35 A0771666 Rear Terminal Holder 1 11 36 Denotes new part The chart listed below shows the Last Bulletin Number issued for the A151 A152 A202 A203 series Bulletin Cross Reference Ricoh Group Companies Last Bulletin No Gestetner 011 Ricoh 017 Sav...

Page 390: ...s and hold the Clear Stop key until a dot z appears in the top left corner of the Copy Counter and then release the Clear Stop key 4 Press the Clear Stop key again and then depress the Lighter key A 5 will blink in the Copy Counter to indicate that SP Mode has been accessed 5 Enter SP 97 using the number keys Then press the Auto ID key Enter 1 then press the Auto ID key 6 Turn the Main Switch OFF ...

Page 391: ... normal NSPC channels NOTE For more information about the Ricoh Technical Services BBS order the Guide to Operation P N BBS00001 through normal NSPC channels UNITS AFFECTED All copiers manufactured after the Serial Numbers listed below will have the new style ROM installed during production MODEL NAME SERIAL NUMBER Gestetner 2713 ROM E AJ87890001 Ricoh FT3513 ROM E A7407900066 Savin 9113 ROM E 7A9...

Page 392: ...NSERT GENERAL The Service Manual pages listed below must be replaced with the pages supplied Each bulletin package contains 1 set of replacement pages PAGES The revised areas have been highlighted by an arrow A202 A203 8 41 Corrected Information SP 57 8 42 Corrected Information SP 66 SP 69 Note This copy intended as master original for reproduction of additional bulletins SERVICE MANUAL ...

Page 393: ...LUTION A new style Cleaning Blade with impact resilience lower than the present Cleaning Blade has been designed This Cleaning Blade has been tested with good results in eliminating the noise problem GENERAL The following part update is being issued for all A151 and A152 Parts Catalogs REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM AD002044 A1519532 Cleaning Blade 1 29 9 NOTE The new ...

Page 394: ...0 Decal Model Name SVN 1 7 20 A2038680 Decal Model Name SVN 1 7 20 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be us...

Page 395: ...er cut in not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3...

Page 396: ...wing part correction is being issued for all A202 and A203 Parts Catalogs Please update your Parts Catalogs with the following information REFERENCE INCORRECT PART NO CORRECT PART NO DESCRIPTION PAGE ITEM 12041576 A1905222 Main Switch 41 105 UNITS AFFECTED A202 and A203 Serial Number cut ins not available at time of publication Note This copy is intended as a master original for reproduction of ad...

Page 397: ... 3513 3713 SAVIN 9113 9113Z SUBJECT BOTTLE DRIVE MOTOR GENERAL The following part correction is being issued for all A202 A203 Parts Catalogs REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A2031166 A2031165 Bottle Drive Motor 1 1 1 43 15 Note This copy is intended as a master original for reproduction of additional bulletins PARTS CONTROL NO 031ABW ...

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