Ricoh A151 Field Service Manual
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Ricoh A151 Field Service Manual

Ricoh laser mfp field service manual
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Table of Contents

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A151/A152/A202/A203

SERVICE MANUAL

PN: RCFM3213
RICOH GROUP COMPANIES

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Summary of Contents for Ricoh A151

  • Page 1: Service Manual

    A151/A152/A202/A203 SERVICE MANUAL PN: RCFM3213 RICOH GROUP COMPANIES...
  • Page 2 RICOH GROUP COMPANIES...
  • Page 3 A151/A152/A202/A203 FIELD SERVICE MANUAL PN: RCFM3213...
  • Page 5 It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
  • Page 7 Th e Field Service Man ual contains infor mation regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.
  • Page 9 LEGEND PRODUCT CODE COMPANY GESTETNER 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 6/96 Reprint 4/97 A202/A203 Addition 7/98 Reprint...

  • Page 11: Table Of Contents

    ....4-2 1.4 OPTICS ..... . 4-3 A151/A152/A202/A203...
  • Page 12 ... 4-32 5.3 REGULAR PM PROCEDURE ... . . 4-34 6. DEFECTIVE COMPONENT TABLES ..4-36 A151/A152/A202/A203...
  • Page 13 2.7.2 Wire Installation ....5-15 2.8 SCANNER MOTOR REPLACEMENT ..5-21 2.9 LENS DRIVE MOTOR REPLACEMENT (FT3213 Copier only) 5-22 2.10 4TH/5TH MIRROR MOTOR REPLACEMENT (FT3213 Copier Only) 5-24 A151/A152/A202/A203...
  • Page 14 6.7 ID SENSOR REPLACEMENT ... . . 5-51 6.8 PICK-OFF PAWL REPLACEMENT ... . 5-52 6.9 TRANSFER/SEPARATION POWER PACK REPLACEMENT . 5-53 A151/A152/A202/A203...
  • Page 15 8.10 VERTICAL MAGNIFICATION ADJUSTMENT ..5-81 8.11 FOCUS ADJUSTMENT ....5-82 8.12 LEADING EDGE ERASE MARGIN ADJUSTMENT ..5-83 A151/A152/A202/A203...
  • Page 16 1.13 TONER DENSITY TOO LOW ... . . 6-18 1.14 TONER SCATTERING ....6-20 A151/A152/A202/A203...
  • Page 17 3.2 DEFECTIVE SWITCHES OR OTHER ELECTRICAL COMPONENTS ....6-54 3.3 OPEN FUSES & CIRCUIT BREAKERS ..6-55 A151/A152/A202/A203...
  • Page 18 MAJOR DIFFERENCES BETWEEN THE A202/A203 AND A151/A152 COPIERS ....1. SPECIFICATIONS ....
  • Page 19 15.4 SERVICE PROGRAM MODE TABLE ..8-38 15.5 SP MODE 8-INPUT CHECK ....8-46 15.6 SP MODE 9–OUTPUT CHECK ... . 8-47 A151/A152/A202/A203...
  • Page 20 ....7.1 ORIGINAL PICK-UP MECHANISM ... . 9-7 7.2 ORIGINAL SEPARATION MECHANISM ..9-8 A151/A152/A202/A203...
  • Page 21 9.4 FEED ROLLER REPLACEMENT ... . 9-18 9.5 FRICTION BELT REPLACEMENT ... . 9-19 9.6 PICK-UP SOLENOID ADJUSTMENT ... 9-20 A151/A152/A202/A203...

  • Page 23: Important Safety Notices

    3. Toner and developer are non-toxic, but if you get either of them in your eyes by accident, it may cause temporary eye discomfort. Try to remove with eye drops or flush with water as first aid. If unsuccessful, get medical attention. A151/A152...
  • Page 24 4. When keeping used lithium batteries in order to dispose of them later, do not put more than 100 batteries per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up. A151/A152...
  • Page 25 Rev. 4/97 TAB INDEX 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 27 OVERALL MACHINE INFORMATION...

  • Page 29: Specifications

    " x 14") Warm-Up Time: 30 seconds (at 20°C/68°F) First Copy Time: 9 seconds (A4/8 " x 11" lengthwise) Copy Number Input: Number keys, 1 to 99 Manual Image Density: 7 steps Toner Type: Type 320 Developer Type: Type 310 A151/A152...
  • Page 30 713 mm (28.1") 592 mm (23.3") 400 mm (15.7") copy tray Copier with document feeder 713 mm (28.1") 592 mm (23.3") 463 mm (18.2") and copy tray* *NOTE: The document feeder can be installed only on the FT3213 copier. A151/A152...
  • Page 31 (Sales items) Key counter Optional Equipment: Drum anti-condensation heater (Service items) 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 A151/A152...

  • Page 33: Section 2 Guide To Components

    GUIDE TO COMPONENTS...

  • Page 35: Mechanical Component Layout

    19. Cleaning Blade 8. Fusing Unit 31. 2nd Relay Rollers 20. Quenching Lamp 9. Hot Roller 32. By-pass Feed Table 21. Charge Corona Unit 10. Exit Rollers 33. 1st Relay Rollers 22. Lens 11. Copy Tray 23. 6th Mirror A151/A152...

  • Page 36: Electrical Component Layout

    29. Scanner Motor 14. Main Switch 30. 4th/5th Mirror Home Position Sensor 15. Fusing Thermoswitch (FT3213 copier only) 16. Exit Sensor 31. 4th/5th Mirror Motor 17. Exhaust Blower Motor (FT3213 copier only) 18. Optics Thermofuse 32. Main Motor Capacitor A151/A152...

  • Page 37: Electrical Component Descriptions

    Drives the registration rollers. Clutch Magnetic Spring Clutches INDEX SYMBOL NAME FUNCTION Toner Supply MSC1 Drives the toner supply roller. Clutch Relay Roller MSC2 Drives the 1st and 2nd relay rollers. Clutch Paper Feed MSC3 Starts paper feed. Clutch A151/A152...
  • Page 38 Converts the wall outlet ac power input to +5 volts, PCB3 Supply Board +24 volts, and a zero cross signal. Informs the CPU of the selected modes and Operation Panel PCB4 displays the copier status and condition on the Board panel. A151/A152...
  • Page 39 Provides back-up overheat protection around the Thermofuse exposure lamp. Main Motor Start capacitor. Capacitor Switches the fusing lamp on and off. (115 V only) Fusing Triac Note: In the 220V-230V/240V version, the triac is built-in the ac drive board A151/A152...

  • Page 40: Drive Layout

    Fusing and Exit Unit BP6: Timing Belt Pulley G4: Hot Roller Gear G12: Development Gear G7: Relay Gear Development Unit G6: Relay Gear G13: Relay Gear G5: Exit Roller Gear G14: Toner Supply CL Gear Toner Supply CL Toner Supply Unit A151/A152...
  • Page 41 G20: Relay Gear G26: Drum Drive Gear Gear G17: Relay Roller CL Paper Feed CL Gear Feed Rollers Relay Roller CL G16: 2nd Relay Roller Gear 2nd Relay Rollers G18: Relay Gear G19: 1st Relay Roller Gear 1st Relay Rollers A151/A152...

  • Page 43: Section 3 Installation

    INSTALLATION...

  • Page 45: Installation Requirements

    9. Place the machine on a strong and level base. 10. Avoid any area where the machine may be subjected to frequent strong vibration. 1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level A151/A152...

  • Page 46: Minimum Space Requirements

    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. A151/A152...

  • Page 47: Installation Procedure

    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) A151/A152...

  • Page 48: Copier Installation Procedure

    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. A151/A152...
  • Page 49 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 too rapidly. A151/A152...
  • Page 50 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 illustration.) A151/A152...
  • Page 51 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. A151/A152...
  • Page 52 3) Perform SP 65 as follows: SP Mode Number Procedure Enter "65" using the numeral keys and press the Developer Initial Auto Image Density key. "50" will be displayed Setting in the copy counter. Press the Start key for initial setting. A151/A152...
  • Page 53 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. A151/A152...

  • Page 54: Key Counter Holder Installation (Option)

    NOTE: The fixing plate has three different hole sizes. Use the holes that match those on the counter that you are installing. 11. Cut the jumper wire (JP101) [F] with a pair of diagonal cutters or other suitable tool. 12. Reinstall all covers. A151/A152 3-10...

  • Page 55: Section 4 Service Tables

    SERVICE TABLES...

  • Page 57: Service Remarks

    5. Store the drum in a cool, dry place away from heat. 6. Take care not to scratch the drum as the drum layer is thin and can be damaged. 7. Never expose the drum to corrosive gases such as ammonia gas. A151/A152...

  • Page 58: Charge Corona

    5. Clean the charge grid with a blower brush (not with a cloth). 6. The corona height should only be adjusted in the following two cases: a) When the front end block is replaced b) When the drum charge current is uneven A151/A152...

  • Page 59: Optics

    7. Whenever one of the actions listed below needs to be performed, all the following actions must be done in order. a) Optics cleaning b) SP95 (V Correction Reset) c) SP48 (Light Intensity Adjustment) d) SP56 (ADS Reference Voltage Adjustment) 8. Do not adjust VR401 on the AC drive board. A151/A152...

  • Page 60: Development

    When the image density sensor is replaced b) When the main board is replaced c) When the drum has been replaced and Vsg is out of specification d) When there have been problems with toner supply and Vsg is out of specification A151/A152...

  • Page 61: Transfer And Separation

    1. Be careful not to damage the edges of the hot roller strippers or their tension springs. 2. Do not touch the fusing lamp with bare hands. 3. Make sure that the fusing lamp does not touch the inner surface of the hot roller. A151/A152...

  • Page 62: Paper Feed

    5. When replacing a sensor, do not overtighten the screws. This may damage the sensor. 6. If a customer reports that red image areas on the original do not appear on the copy, instruct the customer to select the desired image density by the Manual Image Density keys. A151/A152...
  • Page 63 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. A151/A152...

  • Page 64: Service Program Mode

    6. Press the Auto Image Density key to view the data. NOTE: To enter a different SP mode number, press the Auto Image Density key again. 7. To leave SP mode, open and close the front cover or turn the main switch off and on. A151/A152...

  • Page 65: Change Adjustment Values Or Modes

    Auto Image Density key. (SP mode data are given in the Service Program Mode Table.) 4. To leave SP mode, open/close the front cover or turn off/on the main switch (Access Procedure 1) or turn off DPS 101-2 (Access Procedure 2). A151/A152...

  • Page 66: Memory Clear Procedure

    5. Enter "1" by the numeral key and then press the Auto Image Density key. NOTE: The data "1" blinks 4 times when the above procedure is completed. 6. Turn off the main switch. 7. Turn off DPS101-2 and open-circuit JPS101-C (Lower). A151/A152 4-10...
  • Page 67 9. Clean the optics, sensors, and inside of the copier if necessary. 10. Refer to the "FACTORY SETTING" table located inside the upper slit of the inner cover and enter the data for: (1) SP60: Standard Image Grid Voltage Setting (2) SP62: Standard ID Sensor Grid Voltage Setting 4-11 A151/A152...
  • Page 68 (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...

  • Page 69: Service Program Mode Table

    0: Up Count Up/Down Selects count up or count down. 1: Down Open No function. 0: Reduction Reduce/Enlarge Specifies whether reduction or enlargement is Key Function selected first when the Reduce/Enlarge key is 1: Enlargement (FT3213 copier pressed. only) 4-13 A151/A152...
  • Page 70 Adjustment Registration Adjusts registration. 0–15 Adjustment Default = 8 0.4 mm per step. (+3.2 mm to –2.8 mm) Vertical Adjusts magnification in the paper travel 0–15 Magnification direction. Default = 8 Adjustment 0.2% per step. (–1.6% to +1.4%) A151/A152 4-14...
  • Page 71 The Vsp and Vsg voltage readings are updated every 10 or 5 copies depending on SP35 selection. In free run mode, the Vsg and Vsp readings are updated every copy cycle. Refer to NOTE 4 for FT3013 copier. 4-15 A151/A152...
  • Page 72 Drum Initial Used to set new drum condition. 0: No Setting 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. A151/A152 4-16...
  • Page 73 Refer to NOTE 5. When the PM counter exceeds to the selected setting of SP87, the Magnification indicator (FT3213 copier) or the Copy Counter (FT3013 copier) blinks. PM Counter Resets the PM counter. 0: No Clear 1: Yes Use this mode after performing PM. 4-17 A151/A152...
  • Page 74 Calls call indicator has turned on. 121 Optics Section Displays the total number of "optics section" Service Calls service calls. 122 Exposure Lamp Displays the total number of "exposure lamp" Service Calls service calls. 123 Open No function. A151/A152 4-18...
  • Page 75 SP mode numbers: 8, 37, 41, 42, 43, 44, 45, 47, 48, and 50 NOTE 2: When the data in SP mode 12 is changed from "0" to "1", CN421 on the ac drive board must be repositioned. 4-19 A151/A152...
  • Page 76 The first three digits are displayed in the Magnification Indicator. Press and hold the Lighter key to display the last three digits (six digits in total). NOTE 6: Data will vary depending on factory setting. Refer to "FACTORY SETTING" table located on the upper inner cover. A151/A152 4-20...

  • Page 77: Sp Mode 8-Input Check

    Relay Sensor Paper not detected (HIGH) Paper detected (LOW) ≥ 45°C < 45°C Optics Temperature Scanner HP Sensor Sensor actuated (HIGH) Sensor not actuated (LOW) Lens HP Sensor (FT3213 copier only) 4th/5th Mirror HP Sensor (FT3213 copier only) 4-21 A151/A152...

  • Page 78: Sp Mode 9-Output Check

    Charge Corona + ID Sensor Grid with correction Charge Corona + Vrp Grid with correction 30–37 Development Bias Voltage in 40 volts steps starting at –120 volts Development Bias Voltage = –500 volts 40–48 Grid Voltage in 60 volts steps starting at –400 volts A151/A152 4-22...

  • Page 79: Service Call And User Code Table

    Refer to NOTE. turned on. Fusing Overheat The temperature detected by the thermistor becomes higher than 240°C. Fusing Thermistor Open The temperature detected by the thermistor does not reach 2°C within 20 seconds after the main switch is turned on. 4-23 A151/A152...
  • Page 80 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 Key Counter Not Set Scanner not in Home Position A151/A152 4-24...

  • Page 81: Service Tables

    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 Factory use Factory use +5 volts +24 volts 4-25 A151/A152...

  • Page 82: Dip Switches And Jumper Switches

    JPS101-C (Lower) Open To clear counters by SP98 or to clear all memory by SP99 DF Main Board FUNCTION Normal (Factory setting) Lift Switch Free run (Insert paper) must be ON Solenoid test Motor test All indicators ON A151/A152 4-26...

  • Page 83: Variable Resistors

    Adjusts standard development bias voltage TC/SC Power Pack NUMBER FUNCTION Adjusts transfer corona current Adjusts separation corona current AC Drive Board NUMBER FUNCTION VR401 Adjusts base exposure lamp voltage (Factory use) DF Main Board NUMBER FUNCTION Adjusts original stop position (Factory use) 4-27 A151/A152...

  • Page 84: Special Tools And Lubricants

    Grease (Shinetsu Silicone G-501) 54429106 Drum Shoe 54479104 Shoe Adapter 54209507 Digital Multimeter 54479078 Heat Resistance Grease (MT-78) 52149500 Test Chart OS-A4 (10 pcs/set) 52149501 Test Chart OS-A4 (100 pcs/set) A0779505 Drum Shoe Shaft Adapter 54429101 Setting Powder A151/A152 4-28...

  • Page 85: Preventive Maintenance Schedule

    Cleaning Seal Replace if necessary. Cleaning Blade Dust with setting powder after replacement or cleaning. Refer to NOTE 2. DEVELOPMENT UNIT Developer Replace if necessary. Entrance Seal Drive Gears PAPER FEED Registration Roller Water Relay Roller Water Registration Sensor 4-29 A151/A152...
  • Page 86 Confirm the temperature by SP52. Replace if necessary. OTHERS Exit Roller Water Exit Sensor Ozone Filter Timing Belts DOCUMENT FEEDER PM intervals: number of originals fed (SP106) Transport Belt Belt cleaner Friction Belt Water Pick-up Roller Water Feed Roller Water A151/A152 4-30...
  • Page 87 Clean the 6th mirror with silicone cloth as 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. 4-31 A151/A152...

  • Page 88: Explanation Of Regular Pm

    Used Toner Tank If the used toner tank becomes full, "E70" lights and copying becomes inhibited. To prevent unnecessary EM calls, the used toner tank should be emptied at every visit. A151/A152 4-32...
  • Page 89 A dirty transport belt can leave stains on copies. Clean or replace the belt at regular intervals. Pick-up Roller, When dirty, these rollers and this belt can leave Separation Roller, stains on the copy paper. Clean or replace these Separation Belt parts at regular intervals. 4-33 A151/A152...

  • Page 90: Regular Pm Procedure

    6. Clean the grid plate with blower brush. 4. Cleaning Unit 1. Empty used toner tank. (every 80 K) 2. Clean the cleaning seal. 3. Replace the cleaning blade. Note: Apply setting powder to the surface and edge of the new cleaning blade. A151/A152 4-34...
  • Page 91 3. Perform the developer initial setting by SP65. 10. Copy Quality 4. Adjust the exposure lamp intensity by SP48. 5. Adjust the ADS voltage by SP56. 6. Adjust the Vsg by SP54. 7. Reset the toner end counter (SP58) by SP83. 4-35 A151/A152...

  • Page 92: Defective Component Tables

    (CN117-6) copy paper on the by-pass feed table. Image Density Sensor Stays HIGH The CPU detects an ID sensor abnormal (ID Sensor) condition. The ADS or Manual Image (CN112-1) (S7) Density indicators start blinking. Stays LOW (CN112-1) A151/A152 4-36...

  • Page 93: Defective Switches Or Other Electrical Components

    SC code (E53) is displayed. SHORT Fusing Thermoswitch SC code (E52) is displayed. OPEN (TS) Optics Thermofuse SC code (E11) is displayed. OPEN (TF) Optics Thermistor SC code (E40) is displayed. OPEN (TH2) The Energy Saver Function key blinks. SHORT 4-37 A151/A152...

  • Page 94: Open Fuse & Circuit Breaker Table

    CN1 of the DF connector) ... 220~230 V/240 V machine only Circuit Breaker The copier does not turn on even when the AC power ... 220~230 V/240 V main switch is turned on. supply machine only A151/A152 4-38...
  • Page 95 REPLACEMENT ADJUSTMENT...

  • Page 97: Exterior And Inner Covers

    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. A151/A152...

  • Page 98: Upper Left Cover

    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). A151/A152...

  • Page 99: Upper Cover

    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. A151/A152...

  • Page 100: Inner Cover Removal

    2. Open 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. A151/A152...

  • Page 101: Optics

    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. A151/A152...

  • Page 102: 1St Mirror Removal

    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. A151/A152...
  • Page 103 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). A151/A152...

  • Page 104: 2Nd And 3Rd Mirror Removal

    [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. A151/A152...
  • Page 105 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 SP56). A151/A152...

  • Page 106: 4Th And 5Th Mirror Replacement

    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 perform the necessary SP modes (SP95, SP48, and SP56). A151/A152 5-10...

  • Page 107: Exposure Lamp Replacement

    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 lamp. 8. Take out the exposure lamp. 5-11 A151/A152...
  • Page 108 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). A151/A152 5-12...

  • Page 109: Thermofuse Replacement

    1. Turn off the main switch and unplug 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. 5-13 A151/A152...

  • Page 110: Scanner Drive Wire Replacement

    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). A151/A152 5-14...

  • Page 111: Wire Installation

    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. 5-15 A151/A152...
  • Page 112 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 (front view [E]). 10. Set the pulley on the drive shaft (1 E-ring). A151/A152 5-16...
  • Page 113 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. 5-17 A151/A152...
  • Page 114 [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. A151/A152 5-18...
  • Page 115 (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]. 5-19 A151/A152...
  • Page 116 (1) Loosen the front 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. A151/A152 5-20...

  • Page 117: Scanner Motor Replacement

    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]). 5-21 A151/A152...

  • Page 118: Lens Drive Motor Replacement (Ft3213 Copier Only)

    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. A151/A152 5-22...
  • Page 119 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. 5-23 A151/A152...

  • Page 120: 4Th/5Th Mirror Motor Replacement (Ft3213 Copier Only)

    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. A151/A152 5-24...

  • Page 121: Development And Toner Supply

    3. DEVELOPMENT AND TONER SUPPLY 3.1 DEVELOPMENT 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]. 5-25 A151/A152...

  • Page 122: Toner Supply Unit Removal

    1. Take out the 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.) A151/A152 5-26...

  • Page 123: Developer Replacement

    The copier might be damaged if they are turned in the opposite direction. 6. Reinstall the toner supply unit and set the development unit in the machine. 7. Perform the initial setting for new developer using SP65. 5-27 A151/A152...

  • Page 124: Inlet Seal Removal

    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. A151/A152 5-28...

  • Page 125: Toner Supply Clutch Replacement

    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]). 5-29 A151/A152...

  • Page 126: Development Bias Voltage Adjustment (Sp9-38)

    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 turn off the main switch. A151/A152 5-30...

  • Page 127: Cleaning

    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]. 5-31 A151/A152...

  • Page 128: Cleaning Blade Replacement

    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. A151/A152 5-32...

  • Page 129: Used Toner Collection

    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. 5-33 A151/A152...

  • Page 130: Entrance Seal Replacement

    [F] of the projection on the lower casing. b) Make sure that there are no kinks in the upper edge [K] of the entrance seal. 8. Place the two seals [A] on both sides of the entrance seal as shown. A151/A152 5-34...

  • Page 131: Paper Feed

    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). 5-35 A151/A152...
  • Page 132 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. A151/A152 5-36...

  • Page 133: Paper Tray Switch Replacement

    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. 5-37 A151/A152...

  • Page 134: Relay Sensor And Registration Sensor Replacement

    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). A151/A152 5-38...
  • Page 135 8. Remove the relay sensor [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. 5-39 A151/A152...

  • Page 136: Relay Roller Clutch, Paper Feed Clutch And Registration Clutch Replacement

    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). A151/A152 5-40...
  • Page 137 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. 5-41 A151/A152...

  • Page 138: Around The Drum

    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]. NOTE: When removing the drum, take care not to strike it against any objects. A151/A152 5-42...
  • Page 139 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 ID Sensor Adjustment.) 16. Check the copy quality and perform the necessary SP modes. 5-43 A151/A152...

  • Page 140: Quenching Lamp Replacement

    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. A151/A152 5-44...

  • Page 141: Erase Lamp Replacement

    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. 5-45 A151/A152...

  • Page 142: Charge Corona Wire Replacement

    Do not use any solvents to clean the wires as this will cause uneven charge on the drum. g) Do not damage the grid plate when replacing the corona wires. h) When installing the charge corona unit, make sure that the wires are positioned between the cleaner pads [L]. A151/A152 5-46...

  • Page 143: Charge Corona Grid Plate Replacement

    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). 5-47 A151/A152...

  • Page 144: Transfer/Separation Corona Wire Replacement

    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. A151/A152 5-48...
  • Page 145 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 transfer entrance guide is positioned with a special tool at the factory. 5-49 A151/A152...
  • Page 146 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. A151/A152 5-50...

  • Page 147: Id Sensor Replacement

    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. 5-51 A151/A152...

  • Page 148: Pick-Off Pawl Replacement

    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. A151/A152 5-52...

  • Page 149: Transfer/Separation Power Pack Replacement

    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. 5-53 A151/A152...
  • Page 150 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.) A151/A152 5-54...

  • Page 151: Corona Current Adjustment

    • Cleaning Unit • Charge Corona Unit • TC/SC Corona Unit • Drum Unit 2. Clean or replace each corona wire and clean the corona units with water or alcohol. 3. Remove the upper rear cover (2 screws). 5-55 A151/A152...
  • Page 152 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 as shown above, then connect both multimeter leads as shown to the harness leads. A151/A152 5-56...

  • Page 153: Charge Corona Current Adjustment (Sp9-2)

    10. Adjust the front corona wire height by turning the adjusting screw [D] if the two readings are different. 11. Repeat steps 2 to 10 until the difference between the front and rear reading is no more than 4%. 5-57 A151/A152...
  • Page 154 5. Turn on the main switch, close the front cover safety switch and turn on the charge corona using SP9-2. 6. Adjust the charge corona current to –400 ± 3 µA by turning VR1 on the CC/Grid/Bias power pack. 7. Press the Clear/Stop key and turn off the main switch. A151/A152 5-58...

  • Page 155: Grid Voltage Adjustment (Sp9-48)

    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. 5-59 A151/A152...

  • Page 156: Transfer Corona Current Adjustment (Sp9-5)

    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 the main switch. A151/A152 5-60...

  • Page 157: Separation Corona Current Adjustment (Sp9-6)

    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/Stop key and turn off the main switch. 5-61 A151/A152...

  • Page 158: Fusing

    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]. A151/A152 5-62...

  • Page 159: Fusing Unit Removal

    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 and rear upper unit stoppers [C] (1 screw each). 5-63 A151/A152...
  • Page 160 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. A151/A152 5-64...
  • Page 161 [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. 5-65 A151/A152...

  • Page 162: Hot Roller Replacement

    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. A151/A152 5-66...
  • Page 163 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. 5-67 A151/A152...

  • Page 164: Pressure Roller Replacement

    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. A151/A152 5-68...

  • Page 165: Fusing Lamp Replacement

    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 insulators [F] (front and rear) are properly set in the holders as shown. 5-69 A151/A152...

  • Page 166: Fusing Thermoswitch Replacement

    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]. A151/A152 5-70...

  • Page 167: Fusing Thermistor Replacement

    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). 5-71 A151/A152...

  • Page 168: Fusing Pressure Adjustment

    Weaker Stronger The fusing pressure can be set at three different levels. Adjust the pressure spring position to a stronger setting if poor fusing occurs. If copies subsequently get creased or jams occur in the fusing unit, spring. A151/A152 5-72...

  • Page 169: Copy Quality Adjustment

    The grid voltage and charge corona current adjustment should be done only when replacing the CC/Grid/Bias power pack or to correct certain problems with image density after checking all other possible causes. 5-73 A151/A152...

  • Page 170: Light Intensity Adjustment

    If the image density is too dark: Increase the data number If the image density is too light: Decrease the data number 8. Confirm that the image density is within the adjustment standard. 9. Perform the ADS adjustment. (See ADS Adjustment.) A151/A152 5-74...

  • Page 171: Side-To-Side Exposure Adjustment

    3. If the side-to-side variations of the gray scales are not within the adjustment standard, turn off the main switch and remove the exposure glass. (See Exposure Glass Removal.) 4. Position the adjusting plates [A] so that the copy image meets the adjustment standard. 5-75 A151/A152...

  • Page 172: Image Bias Voltage Adjustment

    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. If the background is dirty: Increase the bias voltage by one step and readjust the light intensity. A151/A152 5-76...

  • Page 173: Toner Density Adjustment

    Adjustment Detect Mode : 15% (Factory Setting) Standard: Fixed Mode : 7% (Factory Setting) Detect Mode : SP31 How to Adjust: Fixed Mode : SP32 Changes the interval that the toner supply clutch How it works: is on. 5-77 A151/A152...

  • Page 174: Id Sensor (Vsg) Adjustment

    Item No. Section Method ID sensor Blower brush QL, Erase Lamp Dry cloth 2. Reinstall all the parts. 3. Check Vsg using SP54. Adjust Vsg by turning VR102 (main board) if Vsg is out of the adjustment standard. A151/A152 5-78...

  • Page 175: Ads (Auto Image Density Sensor) Adjustment

    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. 5-79 A151/A152...

  • Page 176: Horizontal Magnification Adjustment

    3. Confirm that the scanner wire clamps are positioned correctly using the scanner positioning pins. (See Scanner Wire Installation.) 4. Remove the lens cover [A] (2 screws). 5. Loosen screws [B] and move the lens [C] to adjust the magnification. A151/A152 5-80...

  • Page 177: Vertical Magnification Adjustment

    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 exposure glass. 2. Adjust the vertical magnification using SP43. Make three copies to check the magnification. 5-81 A151/A152...

  • Page 178: Focus Adjustment

    4. Loosen a screw [B] and move the 4th/5th mirror assembly to adjust the focus. – FT3213 copier – 1. Make three copies with the test chart. 2. Adjust the focus using SP47. Check the text on the copies. A151/A152 5-82...

  • Page 179: Leading Edge Erase Margin Adjustment

    SP42 (0.4 mm/step, 16 steps) How it works: Changes the registration roller start timing. 1. Place a 150 mm scale perpendicular to the left scale on the exposure glass. 2. Adjust the registration using SP42. Make three copies and check the registration. 5-83 A151/A152...

  • Page 180: Side-To-Side Registration Adjustment

    1. Pull the paper tray out. 2. Move the side fences to the widest position. 3. Remove the bottom plate spacer [A]. 4. Slide the bottom plate [B] to the front side and remove it. 5. Remove two springs [C]. A151/A152 5-84...
  • Page 181 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]. 5-85 A151/A152...
  • Page 182 1. Turn off the main switch 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. A151/A152 5-86...

  • Page 183: 4Th/5Th Mirror Height Adjustment

    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. 5-87 A151/A152...

  • Page 184: Others

    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. A151/A152 5-88...

  • Page 185: 230/240V Conversion

    Change the setting from "0" to "1" using the 220 – 230V to numeral keys. Then, press the Auto Image 240V. Density key. "12" will start blinking. Turn the main switch off and on to exit the SP mode. 5-89 A151/A152...

  • Page 186: Optional Equipment Installation

    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. A151/A152 5-90...

  • Page 187: Drum Anti-Condensation Heater Installation

    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]. 5-91 A151/A152...

  • Page 188: Pre-Transfer Lamp (Ptl) Installation

    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]). A151/A152 5-92...

  • Page 189: Optics Cooling Fan Installation (Ft3013 Copier Only)

    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. 5-93 A151/A152...
  • Page 190 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). A151/A152 5-94...
  • Page 191 • Loosen screw A Torsion Torsion on both sides Spring Spring • Shift the adjusting bracket to ward the torsion spring. • Tighten screws on both sides in positions B and A. Strongest Setting Strongest Setting 5-95 A151/A152...
  • Page 192 •Screw •Screw using holes A and C. [Factory Setting] ↓ [Weak Setting] • Remove the adjusting bracket (2 •Screw screws on each side). • Rotate the •Screw bracket 180° and install it using holes B and A. A151/A152 5-96...

  • Page 193: Section 6 Troubleshooting

    TROUBLESHOOTING...

  • Page 195: Copy Quality

    The drum was exposed to fluorescent light or direct sunlight for a long • period of time. The drum was exposed to ammonia gas or corrosive fumes for a long • period of time. 6. The drum does not rotate. A151/A152...
  • Page 196 Are the development drive gears worn or broken? Replace the drive gears. Does the drum rotate properly? Check drum drive mechanisms such as the drum drive belt and the drum pulleys. Good No Good Reinstall them in the correct position or replace the defective parts. A151/A152...
  • Page 197 (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. A151/A152...

  • Page 198: Dirty Background

    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 Replace the main board. Is the cleaning blade worn? Replace the cleaning blade. Are the erase lamp and/or quenching lamp dirty? Clean the erase lamp, quenching lamp, as required. If toner scattering occurs, see the toner scattering section of the manual. A151/A152...
  • Page 200 If 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...

  • Page 201: Uneven Image Density

    Is the erase lamp or quenching lamp dirty? Clean the erase lamp or quenching lamp. Are the corona wires or grid plate dirty? Clean the corona wires, grid plate, and casings. Adjust the charge corona wire height using a drum shoe. (See Charge Corona Current Adjustment.) A151/A152...

  • Page 202: Vertical Black Bands

    If black bands still appear, go to the next step. Is the edge of the cleaning blade deformed? Replace the cleaning blade. If the inlet seal on the development unit is deformed, replace the inlet seal plate and the seal as a set. A151/A152...

  • Page 203: Vertical Black Lines

    Check whether the drum is scratched or toner is built-up on the drum. If toner is built-up on the drum, clean the drum with a damp cloth. • If the drum is scratched, replace the drum. • NOTE: When replacing the drum, perform drum initial setting using SP66. A151/A152...

  • Page 204: Vertical White Lines Or Bands-1 (Dull Or Blurred)

    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? Replace the grid plate. Replace the charge corona wire. A151/A152 6-10...

  • Page 205: Vertical White Lines Or Bands-2 (Thin, Distinct)

    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 blade • Carrier leakage • When replacing the drum, perform the drum initial setting using SP66. 6-11 A151/A152...

  • Page 206: Horizontal Black/White Lines

    - Action - Is the drum scratched? Replace the drum. Is the hot roller scratched? Replace the hot roller. If toner adheres to the drum surface, clean the drum with water. Also clean or replace the cleaning blade. A151/A152 6-12...

  • Page 207: Jitter

    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. 6-13 A151/A152...

  • Page 208: Black Spots On The Copy Image

    Is there good electrical contact between the charge corona casing and the grid plate? 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...

  • Page 209: Skewed (Optical) Copy Image

    Reposition the mirror correctly. If the spring plates are defective, replace them. Are the stubs of the 4th/5th mirror assembly off the rails? Put the mirror assembly stubs back on the rails. Readjust the height of 4th/5th mirror assembly by turning the adjusting screw. 6-15 A151/A152...

  • Page 210: Toner Density Too High

    Does the toner supply clutch turn even though there is sufficient toner in the development unit? Check the voltage at CN110-1 on the main board. 24 volts 0 volts Replace the main board. Replace the toner supply clutch. Is the copier in fixed mode? A151/A152 6-16...
  • Page 211 Change the value of SP30 from "1" to "0". Is the charge corona current correct? Readjust the charge corona current. Is the grid voltage correct? Readjust the grid voltage. Check SP33. If the setting is greater than "2", reset the value to "0". 6-17 A151/A152...

  • Page 212: Toner Density Too Low

    See the ID Sensor Abnormal Condition section. Does the toner supply clutch rotate? Check the voltage at CN110-1 on the main board. 24 volts 0 volts Replace the toner supply clutch. Replace the main board. Go to A A151/A152 6-18...
  • Page 213 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) 6-19 A151/A152...

  • Page 214: Toner Scattering

    2. The inlet seal on the development unit is out of position. 3. The developer has deteriorated. - Action - Is the toner density too high? See section 1-12 (Toner Density Too High). Is the inlet seal deformed? Replace the inlet seal plate. Replace the developer. A151/A152 6-20...

  • Page 215: Unfused Copy Image

    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. 6-21 A151/A152...

  • Page 216: Paper Misfeed

    Misfeed No misfeed Check which sensor (relay sensor, registration sensor or exit sensor) is defective. If sensors are not defective, replace the main board. Check whether a mechanical or electrical malfunction occurs. Replace the defective parts. A151/A152 6-22...

  • Page 217: Transfer Failure

    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. 6-23 A151/A152...

  • Page 218: Df Original Misfeed Or Skew

    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 friction between the exposure glass and the transport belt. A151/A152 6-24...

  • Page 219: Service Call Conditions

    Replace the main board. Replace the ac drive board. 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 exposure lamp circuit open? Open 6-25 A151/A152...
  • Page 220 Open Replace the exposure lamp. Is the thermofuse open? Open Replace the thermofuse. Is the exposure lamp harness defective? Replace the exposure lamp harness. Replace the main board. A151/A152 6-26...

  • Page 221: Code #12 - Exposure Lamp Error

    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. 6-27 A151/A152...

  • Page 222: Code #13 - Zero Cross Signal Error

    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 the dc harness. Replace the main board. A151/A152 6-28...

  • Page 223: Code #21 - Scanner Home Position Error

    Check FU202 on the dc power supply board. Good No Good Replace FU202 Replace the dc power supply board. Check the voltage at CN105-1 and 6 on the main board. 24 volts 0 volts Replace the main board. 6-29 A151/A152...
  • Page 224 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. Replace the scanner H.P. sensor. Replace the main board. A151/A152 6-30...

  • Page 225: Code #22 - Scanner Home Position Error

    Check FU202 on the dc power supply board. Good No Good Replace FU202 Replace the dc power supply board. Check the voltage at CN105-1 and 6 on the main board. 24 volts 0 volts Replace the main board. 6-31 A151/A152...
  • Page 226 Is there 0 volts at CN103-11 on the main board when the scanner H.P. sensor is deactuated? Replace the main hoard Check if the dc harness (signal line) for the sensor is defective. Defective Replace the dc harness. Replace the scanner H.P. sensor A151/A152 6-32...

  • Page 227: Code #28 - Lens Home Position Error (Ft3213 Copier Only)

    24 volts 0 volts Replace the main board. Check the voltage at CN103-2 to 5 on the main board when the main switch is turned on. 17 volts 24 volts Replace the main board. Replace the lens motor. 6-33 A151/A152...
  • Page 228 Is there 5 volts at CN103-8 on the main board when the lens H.P. sensor is actuated? Replace the lens H.P. sensor. Replace the main board. A151/A152 6-34...

  • Page 229: Code #29 - Lens Home Position Error (Ft3213 Copier Only)

    24 volts 0 volts Replace the main board. Check the voltage at CN103-2 to 5 on the main board when the main switch is turned on. 17 volts 24 volts Replace the main board. Replace the lens motor. 6-35 A151/A152...
  • Page 230 Is there 0 volts at CN103-8 on the main board when the lens H.P. sensor is deactuaed? Replace the main board. Check whether the dc harness (signal line) for the sensor is defective. Defective Replace the dc harness. Replace the lens H.P. sensor. A151/A152 6-36...

  • Page 231: Code #2A - 4Th/5Th Mirror Home Position Error (Ft3213 Copier Only)

    24 volts 0 volts Replace the main board. Check the voltage at CN104-2 to 5 on the main board when the main switch is turned on. 16 volts 24 volts Replace the main board. Replace the 4th/5th mirror motor. 6-37 A151/A152...
  • Page 232 Is there 5 volts at CN102-2 on the main board when the 4th/5th mirror H.P. sensor is actuated? Replace the 4th/5th mirror H.P. sensor. Replace the main board. A151/A152 6-38...

  • Page 233: Code #2B - 4Th/5Th Mirror Home Position Error (Ft3213 Copier Only)

    24 volts 0 volts Replace the main board. Check the voltage at CN104-2 to 5 on the main board when the main switch is turned on. 16 volts 24 volts Replace the main board Replace the 4th/5th mirror motor. 6-39 A151/A152...
  • Page 234 Is there 0 volts at CN102-2 on the main board when the 4th/5th mirror H.P. sensor is deactuated? Replace the main board. Check whether the dc harness (signal line) for the sensor is defective. Replace the dc harness. Replace the 4th/5th mirror H.P. sensor. A151/A152 6-40...

  • Page 235: Code #40 - Optics Thermistor Error

    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 6-41 A151/A152...

  • Page 236: Code #52 - Fusing Warm-Up Error

    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? Replace the fusing lamp. Is the thermoswitch open? Replace the thermoswitch. If the ac harness is defective, replace it. A151/A152 6-42...
  • Page 237 Replace the main board. Does the thermistor properly contact the hot roller? Correctly position the thermistor. Does the voltage at TP102 on the main board increase after the main switch is turned on? Replace the thermistor. Replace the ac drive board. 6-43 A151/A152...

  • Page 238: Code #53 - Fusing Overheat

    Replace the main board. Has the thermistor shorted? 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...

  • Page 239: Code #55 - Fusing Thermistor Open

    Clear the service call condition. Does the fusing lamp turn on? Replace the main board. Is the fusing lamp open? Replace the fusing lamp. Is the thermoswitch open? Replace the thermoswitch. Is the ac harness defective? Replace the ac harness. 6-45 A151/A152...
  • Page 240 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...

  • Page 241: Code #96 - Df Timing Pulse Error

    Turn on DIP switches 1, 3 and 4 on the DF main board and turn on the lift switch. Check the voltage at CN117-1 on the DF main board. 0 volts 23 volts Replace the DF motor. Replace the DF main board. 6-47 A151/A152...
  • Page 242 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...

  • Page 243: Df Communication Error

    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 • 6-49 A151/A152...

  • Page 244: Abnormal Condition In Toner Density Detection

    Is the ID sensor surface dirty with toner? Clean the ID sensor with a blower brush and, if needed, with a damp cloth, then check and adjust Vsg to 4.0 ± 0.2 volts. If toner scattering occurs, correct it. (Refer to the Toner Scattering section.) A151/A152 6-50...
  • Page 245 Is Vsg less than 2.5 volts when checking TP110 on the main board with SP 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. 6-51 A151/A152...

  • Page 246: Optics Over Heat Protection (Ft3013 Copier Only)

    Notify the customer that the machine may stop when excessive continuous copy jobs are performed. NOTE: The same optics cooling fan as for the FT3213 copier can be installed on this machine as an optional service part. (See section 5 for the installation procedure.) A151/A152 6-52...

  • Page 247: Defective Sensor Table

    Image Density Sensor Stays HIGH The CPU detects an ID sensor abnormal (ID Sensor) (CN112-1) condition. The ADS or Manual Image (S7) Density indicators start blinking. Stays LOW (CN112-1) 6-53 A151/A152...

  • Page 248: Defective Switches Or Other Electrical

    SC code (E53) is displayed. Fusing Thermoswitch OPEN SC code (E52) is displayed. (TS) Optics Thermofuse OPEN SC code (E11) is displayed. (TF) Optics Thermistor OPEN SC code (E40) is displayed. (TH2) SHORT The Energy Saver Function key blinks. A151/A152 6-54...
  • Page 249 CN1 of the DF connector) ... 220~230 V/240 V machine only Circuit Breaker AC power supply The copier does not turn on even when ... 220~230 V/240 V the main switch is turned on. machine only 6-55 A151/A152...
  • Page 251 DOCUMENT FEEDER A296...

  • Page 253: Specifications

    FT3213. These accessory parts include (1) ADF Interface Bracket Assy. P/N A3650661 & (2) Shoulder screws P/N A0771361. NOTE: PM items for the document feeder can be found on copier PM table page 4-30. A151/A152...
  • Page 254 7. Insert Original Indicator 2. Registration Sensor 8. Original Misfeed Indicator 3. Original Set Sensor 9. Lift Switch 4. Feed Clutch 10. DF Main Board 5. Pulse Generator Sensor 11. DF Transformer 6. DF Motor 12. DF Interface Board A151/A152...
  • Page 255 Transformer DF Transformer Steps down the wall voltage to 25 volts ac. LEDs LED1 Original Misfeed Turns on when an original is misdeed. Indicator LED2 Insert Original Turns off when the originals are inserted into Indicator the original table. A151/A152...
  • Page 256 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. A151/A152...
  • Page 257 [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]. A151/A152...
  • Page 258 12. 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]. A151/A152...
  • Page 259 (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. A151/A152...

  • Page 260: Replacement And Adjustment

    (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. A151/A152...
  • Page 261 7. Remove the transport roller holder [A] (1 screw, 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. A151/A152...
  • Page 262 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. A151/A152 7-10...
  • Page 263 1. Turn off 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]. 7-11 A151/A152...

  • Page 264: Feed Roller Replacement

    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. A151/A152 7-12...
  • Page 265 2. Remove 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.) 7-13 A151/A152...
  • Page 266 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. A151/A152 7-14...
  • Page 267 The A202 copier is based on the A151 copier. The A203 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...
  • Page 269 MAJOR DIFFERENCES BETWEEN THE A202/A203 AND A151/A152. The following table lists the major differences between the A202/A203 series and the A151/A152 series. A "Model Cross Reference Table" can be found in the Specifications Section of the service manual. Item A202/A203...
  • Page 270 Item A202/A203 A151/A152 Electrical Component Fusing Triac The fusing triac is built In the 115V machines, into the ac drive board for the fusing triac is a all models. separate electrical component. Power Distribution Quenching The quenching lamp The quenching lamp...
  • Page 271 A151/A152 clears the E5 conditions by turning off on the DPS101-1. 111 Total Service Calls Same as the A151/A152 2. Eliminate SP Modes compared to the A151/A152 Model Name Comment 220 ~ 230 V/240 Conversion The ac drive board is designed for 230V Open Can not be entered.
  • Page 272 MAJOR UNIQUE PARTS FOR A202/A203 SERIES (Compared with the A151/A152 series) PM Parts Part Number Description A2032632 PICK UP ROLLER ASS’Y Electrical Parts Part Number Description A2031166 BOTTLE DRIVE MOTOR A2031169 FAN MOTOR - 24 V 3.6 W A2031183 MAIN MOTOR - AC 220V 120 W...
  • Page 273 MAJOR UNIQUE 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 A202/A203...
  • Page 275 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that the optional anti-condensation heaters are supplied with electrical voltage even if the main switch is turned off.
  • Page 276 OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1. The copier and its peripherals must be installed and maintained by a customer service representative who has completed the training course 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.
  • Page 277 A202/A203 SERVICE MANUAL...
  • Page 279 SPECIFICATIONS 1. SPECIFICATIONS NOTE: Items marked with an are different from the A151 and A152 copiers. Configuration: Desk top Copy Process: Dry electrostatic transfer system Original Type: Sheet/Book Original Alignment: Left center Original Size: Maximum: A3/11" x 17" (lengthwise) - A203 copier B4/10"...
  • Page 280 Paper tray – 250 sheets or less than 28 mm stack height Bypass feed table – 1 sheet Toner Replenishment: Cartridge exchange (320 g/cartridge) Toner Type: Type 320 (Ricoh Corp. EDP # 887716) Developer Type: Type 310 (Ricoh Corp EDP# 889268) Copy Tray Capacity: 100 sheets (B4/10"...
  • Page 281 Key counter Optional Equipment: Drum anti-condensation heater (Service items) Optics anti-condensation heater Pre-transfer lamp • Specifications are subject to change without notice. Cross Reference Table: Gestetner/Nashau Product Code Ricoh Model Name Savin Tec. A202 FT3513 9113 2713/2713S A203 FT3713 9113Z 2713Z/3713...

  • Page 282: Copy Process Control

    COPY PROCESS CONTROL 2. COPY PROCESS CONTROL • Drum residual voltage (V ) correction and detection have been eliminated. • Drum wear correction has been eliminated. Exposure Lamp Development Bias Grid Voltage Erase Lamp Voltage Voltage Image Standard image Depends on Base exposure Base bias voltage Density...
  • Page 283 MECHANICAL COMPONENT LAYOUT 3. MECHANICAL COMPONENT LAYOUT NOTE: Items marked with an are different from the A151 and A152 copiers. 16 17 18 19 20 22 23 24 A203V500.img 1. Semicircular Feed 11. Copy Tray 23. 6th Mirror Rollers 12. Hot Roller Strippers 24.

  • Page 284: Electrical Component Layout

    38. Paper Feed Clutch 15. Fusing Thermoswitch NOTE: Index No. 28 is not applicable for the A202/A203 models. This item was the Fusing Traic (115V only) in the A151/A152 copiers and is not used on these models (see next page). A202/A203...

  • Page 285: Electrical Component Descriptions

    Switches the fusing lamp on and off. (115 V only) The following part has been changed. Symbol Name Function Index No. Quenching Lamp Receives dc power from the main board (the lamp in the A151/A152 received ac power from the ac drive board). A202/A203...

  • Page 286: Drive Layout

    DRIVE LAYOUT 6. DRIVE LAYOUT NOTE: items marked with an are different from the A151 and A152 copiers. BP5 G11 G10 G23 G20 G21 G22 BP2 BP1 G1 G2 A203V502.img A203V503.img G 1 : Main Motor Gear G 2 :...
  • Page 287 DRIVE LAYOUT Paper Feed Section G 2 4 : Timing Belt Drive G e a r B P 2 : Timing Belt Pulley B P 3 : Timing Belt Pulley Registration CL Gear G 2 2 : Relay Gear TB2: Timing Belt Registration CL Paper Feed Section...
  • Page 288 7. POWER DISTRIBUTION NOTE: Items marked with an are different from the A151 and A152 copiers. A C P o w e r ( 1 1 5 V o r 2 2 0 V ~ 2 4 0 V )
  • Page 289 POWER DISTRIBUTION The main board supplies dc power to all copier dc components. All sensors, switches, thermistors, and the DF interface board (option) operate on +5 volts. The operation panel operates on +5 volts supplied by the main board. All other dc components, including the power relay (RA401) and the main motor relay (RA402), operate on +24 volts.

  • Page 290: Drum Charge

    DRUM CHARGE 8. DRUM CHARGE 8.1 GRID VOLTAGE CORRECTION This machine does not correct drum residual voltage correction (V correction) or drum wear correction. 8.2 GRID VOLTAGE FOR IMAGE DENSITY CONTROL The main board controls the grid voltage through the CC/Grid/Bias power pack.

  • Page 291: Grid Voltage For Toner Density Detection

    DRUM CHARGE 8.3 GRID VOLTAGE FOR TONER DENSITY DETECTION The grid voltage for toner density detection is based on the standard ID sensor grid 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.

  • Page 292: Lens Positioning

    OPTICS 9. OPTICS 9.1 LENS POSITIONING : Initialize Home Position (100%) ( 1 0 0 % → 1 4 1 / 1 2 9 % ) ( 1 4 1 / 1 2 9 % → 7 1 / 6 5 % ) A203D501.img ( 7 1 / 6 5 % →...

  • Page 293: Exposure Lamp Control Circuit

    SP48 sets the exposure lamp data for 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...

  • Page 294: Development Bias Circuit

    DEVELOPMENT 10. DEVELOPMENT 10.1 DEVELOPMENT BIAS CIRCUIT Charge Corona Power Pack - CC/Grid/Bias Bias Trig (PWM) [ 0→0/5] (P1) Grid Development Bias A203D505.wmf A203D506.wmf The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1. When the key is pressed, the CPU starts sending the bias trigger pulses to CN1-4.
  • Page 295 Rev. 5/30/97 TONER DENSITY DETECTION AND TONER SUPPLY 11. TONER DENSITY DETECTION AND TONER SUPPLY 11.1 ID Sensor Control Circuit This circuit is different from the A151 and A152 copiers at the (dashed circle) indicated location. +24V (VA) (VB) A203D509.wmf...

  • Page 296: Toner Supply And Agitator Drive Mechanism

    TONER DENSITY DETECTION AND TONER SUPPLY 11.2 TONER SUPPLY AND AGITATOR DRIVE MECHANISM A203D508.wmf A207D507.img When the toner supply motor [A] energizes, the toner supply drive gear [B] starts turning and drives the toner supply roller gear [C]. Toner catches in the grooves on the toner supply roller [D].

  • Page 297: Paper Length Detection (Paper Feed Station)

    PAPER FEED 12. PAPER FEED 12.1 PAPER LENGTH DETECTION (Paper Feed Station) The paper length is measured by the registration sensor while paper is fed past the registration sensor. The determined paper size is stored in memory. This is performed during the first copy of a copy job. As shown by the following table, the CPU determines the size of the paper in the paper tray based on the paper length measured by the registration sensor.

  • Page 298: Image Fusing

    IMAGE FUSING 13. IMAGE FUSING 13.1 FUSING LAMP CONTROL CIRCUIT The circuit of the main board is different from the A151 and A152 copiers at the indicated (dashed circle) location. T401 A203D510.wmf 13.2 OVERHEAT PROTECTION IC120 and Q101 form an overheat protection circuit. When the fusing lamp is controlled within the normal range, pin 1 of IC120 stays LOW;...

  • Page 299: Copier (A202/A203) Accessory Check

    INSTALLATION 14. INSTALLATION 14.1 COPIER (A202/A203) ACCESSORY CHECK Check the quality and condition of the accessories in the box against the following list: 1. Model Name Decal (-10, -22 machines) 2. Symbol Explanation Decal - English 3. Symbol Explanation Decal - Multi-language (-26 machines) 4.

  • Page 300: Copier (A202/A203) Installation Procedure

    INSTALLATION 14.2 COPIER (A202/A203) INSTALLATION PROCEDURE A203I500.wmf A203I501.wmf 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. A202/A203 8-22...
  • Page 301 INSTALLATION A203I502.img A203I503.img A203I504.img 3. Open the platen cover [A] and remove the lock pins [B]. (A202 copier: 2 pins, A203 copier: 4 pins) NOTE: Save the lock pins for future shipping use. 4. Open the front cover [C], and remove the foam block [D]. 5.
  • Page 302 INSTALLATION A203I505.img A203I506.img A203I508.img A203I507.img 7. Remove development unit retaining screws [H] (2 screws) and while pulling the left side of the development cover [B] carefully pull out the development unit. Place the development unit on a clean sheet of paper. 8.
  • Page 303 INSTALLATION A203I509.img A203I510.img 11. Reinstall the development unit. 12. Shake well a toner cartridge [A], check 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.
  • Page 304 Rev. 5/30/97 INSTALLATION 14. Do the developer initial setting procedure. 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 number keys. b) Press and hold the key until a dot (•) appears in the top left corner of the copy counter.
  • Page 305 INSTALLATION A203I511.wmf A203I512.wmf A203I513.wmf A203I514.wmf 15. Place the decal [A] (symbol explanation) on the platen cover as shown, or when the DF [B] is installed on the machine, place the decal on the DF as shown. 16. Install the copy tray [C]. 17.

  • Page 306: Document Feeder (A662) Accessory Check

    INSTALLATION 14.3 DOCUMENT FEEDER (A662) ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Voltage Reference Decal..........1 2. Thumb Screw M4 x 12............2 3. Stud Screw (M3) ............... 2 4. Installation Procedure - English........1 5.
  • Page 307 INSTALLATION 14.4 DOCUMENT FEEDER (A662) INSTALLATION PROCEDURE [F] 230 ~ 240 V [D] 220 ~ 230 V A662I517.wmf A662I501.img CAUTION When installing the DF, make sure that the copier is unplugged. 1. Remove the platen cover [A] from the copier. 2.
  • Page 308 INSTALLATION A662I506.img A662I507.img A662I513.wmf 5. Insert the DF [A] into the slots [B] in the copier upper cover. 6. Secure the DF to the copier (2 thumb screws [C]). 7. Remove the upper rear cover [D] (2 screws). 8. Remove the ADF bracket [E] (1 screw and 1 clamp). 9.
  • Page 309 INSTALLATION A662I508.img 11. Locate the 4P connector [A] and connect it to the ADF interface board [B], A662I509.img then attach the ADF interface unit [C] to the copier (1 screw) while securing the harnesses through the wire clamp. NOTE: Use the screw that secured the ADF bracket. (See the previous page.) 12.
  • Page 310 INSTALLATION A662I510.img A662I511.img A662I512.img 18. Remove 2 screws [A]. 19. Tighten the shorter stepped screw [B]. 20. Install the upper unit stand [C] (1 longer stepped screw [D]). 21. Attach the magnet [E] as shown. 22. Attach the decal [F] as shown. 23.
  • Page 311 INSTALLATION A662I514.img A662I515.img 25. Check that the rubber pad [C] is in contact with the top of the operation panel cover. If it is not, 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.

  • Page 312: Access Procedure 1-Key Operation

    Rev. 5/30/97 SERVICE PROGRAM MODE 15. SERVICE PROGRAM MODE 15.1 ACCESS PROCEDURE 1-KEY OPERATION 1. Turn on the main switch. 2. Enter "71" by using the number keys. 3. Press and hold the key until a dot (•) appears in the top left corner of the Copy Counter and then release it.

  • Page 313: Memory Clear Procedure

    SERVICE PROGRAM MODE 15.2 MEMORY CLEAR PROCEDURE – Clear Counters (SP98) – NOTE: This SP mode clears the following counters: • SP100: By-pass Feed Copies • SP101: Paper Tray Copies • SP103: Total Copies • SP106: DF Originals • SP110: Total Misfeeds •...

  • Page 314: Clear All Memory Procedure

    (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 counter for the development bias voltage in the toner detection cycle has been cleared, –20 volts will be...
  • Page 315 SERVICE PROGRAM MODE 9. Perform the following SP modes in sequence: 1) SP66: Drum Initial Setting 2) SP65: Developer Initial Setting 3) SP48: Light Intensity Adjustment 4) SP56: 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)
  • Page 316 15.4 SERVICE PROGRAM MODE TABLE 1. Items marked with an are different from the A151 and A152 copiers. 2. A "†" after the mode name signifies that copies can be made while in the SP mode. (Copies can be made by pressing the key after pressing key.)
  • Page 317 SERVICE PROGRAM MODE Rev. 5/30/97 Mode No. Function Settings Auto Shut Off Selects an auto reset time of 1 or 3 minutes, or 0: 1 min. Time (Energy cancels this mode. 1: 3 min. Saver Mode) 2: None The copier automatically goes to the energy saver mode at the selected reset time if SP78 is at "1".
  • Page 318 SERVICE PROGRAM MODE Mode No. Function Settings Image Bias Adjusts image bias output if the image density at 0: Normal (Vo) Adjustment † level 4 cannot be adjusted by the Light Intensity 1: Darkest adjustment (SP48). Refer to NOTE 1 2: Darker 3: Lighter 0: Vo...
  • Page 319 Rev. 5/30/97 SERVICE PROGRAM MODE Mode No. Function Settings Exposure Lamp Displays the exposure lamp setting with a 100 ~ 150 Setting Display reference number. The exposure lamp and optics cooling fans turn on for 10 seconds when the key is pressed. Press the key to turn this mode off.
  • Page 320 SERVICE PROGRAM MODE Mode No. Function Settings Standard Image Factory use only. 0 ~ 8 Grid Voltage Do not change the setting. Default = 4 Setting Refer to NOTE 5. Standard ID Factory use only. 0 ~ 8 Sensor Grid Do not change the setting.
  • Page 321 Rev. 7/97 SERVICE PROGRAM MODE Mode No. Function Settings Horizontal Edge Selects whether the side erase mechanism 0: Always stays Margin Width changes when the optional document feeder is in Platen Mode Adjustment installed. 1: DF Mode Compared with the platen mode erase, the next inmost LED block will turn on to erase.
  • Page 322 Rev. 5/30/97 SERVICE PROGRAM MODE Mode No. Function Settings By-pass Feed Displays the total number of copies fed from the Copies by-pass feed table. Refer to NOTE 4. Paper Tray Displays the total number of copies fed from the Copies paper tray.
  • Page 323 Rev. 5/30/97 SERVICE PROGRAM MODE NOTE 3: Make copies or perform free run to display the SP mode setting. The A202 copier displays the SP mode setting in the Copy Counter. Since the Copy Counter has only 2 digits, the first digit is displayed in the Manual Image Density indicator as shown below (digits after the decimal place are displayed in the Copy Counter): : "0"...

  • Page 324: Sp Mode 8-Input Check

    SERVICE PROGRAM MODE Rev. 5/30/97 15.5 SP MODE 8-INPUT CHECK – How to check sensor/switch inputs for the A202 copier – 1. Enter SP mode 8 as outlined in the Service Program Mode Access Procedure on page 8-34, then press the key.

  • Page 325: Sp Mode 9–Output Check

    SERVICE PROGRAM MODE 15.6 SP MODE 9–OUTPUT CHECK – How to turn electrical components on/off – 1. Enter SP mode 9 as outlined in the Service Program Mode Access Procedure on page 8-34, then press the key. 2. Enter the desired number from the following table. 3.

  • Page 326: Test Points

    SERVICE TABLES Rev. 5/30/97 16. SERVICE TABLES 16.1 TEST POINTS Copier Main Board Number Function TP101 HET (Fusing Thermistor) ADS (Auto Image Density Sensor) TP102 Adjust the voltage to +2.5 ± 0.1 volts with VR101. TP103 ETH (Optics Thermistor) PSE (ID Sensor Voltage) TP105 Adjust the voltage to +4.0 ±...
  • Page 327 Rev. 5/30/97 SERVICE TABLES 16.4 SERVICE CALL AND USER CODE TABLE NOTE: Items marked with an are different from the A151 and A152 copiers. Service Call Code NOTE: Due to the small capacity of the system EEPROM, the individual service call counters that were available in previous models of these base copiers have been eliminated.
  • Page 328 SERVICE TABLES Rev. 5/30/97 E-code Contents Note 4th/5th Mirror Home Position Error (A203 copier only) The 4th/5th mirror home position sensor’s output remains HIGH (actuated) for 4.0 seconds after the 4th/5th mirror assembly leaves the home position. Optics Thermistor Error The optics thermistor is defective (open).
  • Page 329 PREVENTIVE MAINTENANCE SCHEDULE 17. PREVENTIVE MAINTENANCE SCHEDULE 17.1 PM TABLE The DF section has been changed. The copier section is the same. 80 k 160k Notes DOCUMENT FEEDER (A662) (for originals) Transport Belt Belt cleaner Friction Belt Belt cleaner Pick-up Roller Soft cloth dampened with water Feed Roller Soft cloth dampened with water...
  • Page 330 REPLACEMENT AND ADJUSTMENT Rev. 5/30/97 18. REPLACEMENT AND ADJUSTMENT 18.1 TONER SUPPLY MOTOR REPLACEMENT A203R500.wmf 1. Turn off the main switch. 2. Remove the upper rear cover and main control board (all connectors and 4 locking supports). 3. Remove the toner supply motor bracket [A] (3 screws). 4.
  • Page 331 REPLACEMENT AND ADJUSTMENT 18.2 QUENCHING LAMP REPLACEMENT A203R501.wmf 1. Open the front cover. 2. Remove the following parts: • Inner cover (Refer to Inner Cover Removal procedure). • Development unit (Refer to the Development Unit Removal procedure). • Cleaning unit (Refer to the Cleaning Unit Removal procedure). •...

  • Page 332: Charge Corona Current Adjustment

    REPLACEMENT AND ADJUSTMENT 18.3 CHARGE CORONA CURRENT ADJUSTMENT A203R502.img ADJUSTMENT STANDARD Adjusting VR SP Mode DC –400 ± 3 µA SP9-2 NOTE: 1) VRC on the CC/Grid/Bias power pack spare parts is pre-adjusted. Usually it is not necessary to adjust VRC when the CC/Grid/Bias power pack is replaced.
  • Page 333 REPLACEMENT AND ADJUSTMENT 18.4 GRID VOLTAGE ADJUSTMENT (SP9-46) A203R503.img ADJUSTMENT STANDARD Adjusting VR SP Mode DC –760 ± 10 Vdc SP9-46 NOTE: VRG on the CC/Grid/Bias power pack spare parts is pre-adjusted. Usually it is not necessary to adjust VRG when the CC/Grid/Bias power pack is replaced.
  • Page 334 REPLACEMENT AND ADJUSTMENT 18.5 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT (SP9-38) A203R504.img ADJUSTMENT STANDARD Adjusting VR SP Mode DC –500 ± 10 V SP9-38 NOTE: VRB on the CC/Grid/Bias power pack spare parts is pre-adjusted. Usually it is not necessary to adjust VRB when the CC/Grid/Bias power pack is replaced.
  • Page 335 Rev. 7/97 REPLACEMENT AND ADJUSTMENT 18.6 TRANSFER CORONA CURRENT ADJUSTMENT (SP9-5) A203R505.img A203R506.img A203R507.img ADJUSTMENT STANDARD Adjusting VR SP Mode DC –31.0 ± 0.5 µA SP9-5 1. If previously removed, reinstall the TC/SC corona unit and position the drum shoe [A] on the center of the shaft so that the axis of the current detection plate [B] is aligned with the transfer corona wire as shown.
  • Page 336 REPLACEMENT AND ADJUSTMENT Rev. 7/97 18.7 SEPARATION CORONA CURRENT ADJUSTMENT (SP9-6) A203R508.img A203R506-2.img A203R509.img ADJUSTMENT STANDARD Adjusting VR SP Mode AC 49 ± 1.0 µA SP9-6 1. If previously removed, reinstall the TC/SC corona unit and position the drum shoe [A] on the center of the shaft so that the axis of the current detection plate [B] is aligned with the separation corona wire as shown.
  • Page 337 DOCUMENT FEEDER A662...
  • Page 339 Rev. 5/30/97 SPECIFICATIONS 1. SPECIFICATIONS Original Size: Maximum: A3 or 11" x 17" Minimum: A5 Lengthwise or 5 " x 8 " Original Weight: 52 to 105 g/m (14 to 28 lb) Original Feed: Automatic Feed - ADF mode Semi-automatic Feed - SADF mode Original Tray Capacity: 30 sheets - 80 g/m (20 lb)

  • Page 340: Mechanical Components

    COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENTS A662V500.img 1. Pulse Generator Disk 6. Exit Roller 2. Friction Belt 7. Transport Belt 3. Pick-up Lever 8. Transport Belt Roller 4. Pick-up Roller 9. Feed Roller 5. Original Table 10. Relay Roller 2.2 ELECTRICAL COMPONENTS A662V501.img A662V502.img...
  • Page 341 ELECTRICAL COMPONENT DESCRIPTIONS 3. ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Motor DF Motor Drives all the document feeder components. Solenoid Pick-up Solenoid Energizes to press the pick-up lever against SOL1 the stack of originals in preparation for original feed-in. Clutch Feed Clutch Turns on to transmit main motor rotation to...
  • Page 342 POWER DISTRIBUTION 4. POWER DISTRIBUTION A662D500.wmf The document feeder uses two dc power levels: +24 volts, and +5 volts. When the main switch is turned on, the DF transformer receives the wall outlet ac power through the ac drive board and outputs 25 volts ac to the DF main board.

  • Page 343: Basic Operation

    BASIC OPERATION 5. BASIC OPERATION When the main switch is turned on, the DF CPU sends the "DF installed" signal to the copier CPU. Receiving this signal, the copier CPU recognizes that the document feeder is installed and sends the "DF confirmed" signal to the DF CPU.

  • Page 344: Interface Circuit

    INTERFACE CIRCUIT 6. INTERFACE CIRCUIT A662D509.wmf 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). A202/A203...

  • Page 345: Original Feed

    ORIGINAL FEED 7. ORIGINAL FEED 7.1 ORIGINAL PICK-UP MECHANISM A662D502.img After setting the originals on the original table, the originals contact the feeler [A] of the original set sensor and cause the feeler to move out of the sensor. The DF CPU then sends the original set signal to the copier CPU to inform it that the document feeder will be used.

  • Page 346: Original Separation Mechanism

    ORIGINAL FEED 7.2 ORIGINAL SEPARATION MECHANISM A662D503.img A662D504.img The feed roller [A] and the friction belt [B] are used to feed in and separate the originals [C]. Only the bottom original is fed because the friction belt prevents any other originals from feeding. Original feed starts when the pick-up lever [D] presses the original stack and the pick-up roller [E] advances the bottom original of the stack.
  • Page 347 ORIGINAL FEED 7.3 ORIGINAL FEED-IN MECHANISM A662D505.img The DF motor [A] drives the feed roller [B], the pick-up roller [C], the relay rollers [D], and the transport belt roller [E] via timing belts and a gear train. The feed roller and the pick-up roller are controlled by the feed clutch [F], but the relay rollers and the transport roller are directly driven by the DF motor.
  • Page 348 ORIGINAL FEED 7.4 ORIGINAL FEED-OUT MECHANISM A662D506.img The exit rollers [D] are driven by the DF motor through a series of gears, the transport belt [A], 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.
  • Page 349 ORIGINAL FEED 7.5 DF MOTOR CIRCUIT A662D507.wmf The DF motor is a 24 volt dc motor. When the CPU receives the feed signal from the copier, the CPU outputs the ON signal and the Forward signal to the gate IC. On receipt of the forward signal from the gate IC, the driver IC outputs 24 volts to CN117-1 and 0 volts to CN117-2.
  • Page 350 ORIGINAL FEED 7.6 ORIGINAL FEED AND MISFEED DETECTION TIMING A662D508.wmf The above chart shows the original feed timing for A4 lengthwise or 8.5" x 11" originals, and the misfeed detection timing. The registration sensor is used for misfeed detection. If the DF CPU detects a misfeed, the DF CPU lights the Original Misfeed indicator and sends the original misfeed signal to the copier CPU.

  • Page 351: Dip Switches

    SERVICE TABLES 8. SERVICE TABLES 8.1 DIP SWITCHES DPS 1 Function Normal Setting Free Run Solenoid Test Motor Test All Indicators On NOTE: All the functions are executed when the DF is closed. 8.2 VARIABLE RESISTORS VR No. Function Adjusts registration 8.3 FUSE Fuse No.

  • Page 352: Transport Belt Replacement

    REPLACEMENT AND ADJUSTMENT 9. REPLACEMENT AND ADJUSTMENT 9.1 TRANSPORT BELT REPLACEMENT A662R500.img A662R501.img 1. Turn off the main switch. 2. Remove the original table [A]. 3. Remove the DF [B] from the copier (2 knob screws, 1 power supply cord, and 1 optics harness).
  • Page 353 REPLACEMENT AND ADJUSTMENT A662R502.img 7. Remove the transport roller holder [A] (1 screw, 1 snap ring and 1 bearing). 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.
  • Page 354 REPLACEMENT AND ADJUSTMENT 9.2 FEED-IN UNIT REMOVAL A662R503.img 1. Turn off the main switch. 2. Remove the transport belt assembly. (See Transport Belt Replacement.) 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).
  • Page 355 REPLACEMENT AND ADJUSTMENT 9.3 PICK-UP ROLLER REPLACEMENT A662R504.img 1. Turn off 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]. 9-17 A202/A203...
  • Page 356 REPLACEMENT AND ADJUSTMENT 9.4 FEED ROLLER REPLACEMENT A662R505.img 1. Turn off the main switch. 2. Remove the feed-in unit. (See Feed-in Unit Removal.) 3. Remove the feed roller timing belt [A], feed roller gear [B] (1 E-ring and 1 spring pin [C]) and 1 bushing [D]. NOTE: Be careful not to lose the spring pin.

  • Page 357: Friction Belt Replacement

    REPLACEMENT AND ADJUSTMENT 9.5 FRICTION BELT REPLACEMENT A662R507.img A662R506.img 1. Turn off the main switch. 2. Remove 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 fiction belt roller is set in the correct position.
  • Page 358 REPLACEMENT AND ADJUSTMENT 9.6 PICK-UP SOLENOID ADJUSTMENT A662R508.img 1. Turn off the main switch. 2. Remove the feed-in unit. (See Feed-in Unit Removal.) 3. Loosen two screws [A] securing the pick-up solenoid [B]. 4. Place a 1.2 mm thickness gauge [C] between the plunger and the solenoid.
  • Page 359 TECHNICAL SERVICE BULLETINS...
  • Page 361 7. Reassemble the machine. ORDERING PROCEDURE: Ricoh Corporation will automatically ship two (2) Plates (A1519900) for use on 100% of all FT3013/32 13 copiers manufactured prior to September, 1994 based on Ricoh’s Equipment Shipped Records. NOTE: The plates are not necessary if a Document Feeder is installed.

  • Page 362: Tech Service Bulletin No. 3013/3213-001 Reissue

    Tech Service Bulletin No. 3013/3213-001 Page 2 of 2 TEMPORARY PRODUCTION COUNTERMEASURE: The shaded areas of the Torsion Bar Angles have been removed to reduce the strength of the Torsion Springs. Torsion Bar Angle Side View The shaded areas have been removed Front Torsion Bar Angle (A0771108) Rear Torsion Bar Angle (A0771098) UNITS AFFECTED:...
  • Page 363 Ricoh Corporation will automatically ship two (2) Plates (A1519900) for use on 100% of all FT3013/3213 copiers manufactured prior to September, 1994 based on Ricoh’s Equipment Shipped Records. NOTE: The plates are not necessary if a Document Feeder is installed.
  • Page 364 Tech Service Bulletin No. 3013/3213-001 REISSUE Page 2 of 2 TEMPORARY PRODUCTION COUNTERMEASURE: Torsion Bar Angle The shaded areas of the Torsion Bar Angles have been removed to reduce the strength of the Torsion Springs. Side View UNITS AFFECTED: All FT3013/3213 copiers manufactured during September, 1994 thru November, 1994 will have the Torsion Bar Angles modified as illustrated during production.
  • Page 365 BULLETIN NUMBER: 3013/3213-002 12/13/94 APPLICABLE MODEL: FT3013/3213 SUBJECT: 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 •...
  • Page 366 BULLETIN NUMBER: 3013/3213-003 12/13/94 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG UPDATES GENERAL: Please correct your Parts Catalog as follows: Part Number Description Parts Catalog Page Item Drum Anti-condensation Heater - 115V A0779501 (Option) Incorrect Drum Anti-condensation Heater - 220V A0779502 (Option) Anti-condensation Heater - 115V 18W AX400021...
  • Page 367 BULLETIN NUMBER: 3013/3213-004 02/09/95 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG CORRECTIONS GENERAL: The following Parts Catalog corrections are being issued for all FT3013/3213 Parts Catalogs. This information should be incorporated into all existing FT3013/3213 Parts Catalog documentation. 1. Please delete the following parts from your Parts Catalog: REFERENCE PART NUMBER DESCRIPTION...
  • Page 368 BULLETIN NUMBER: 3013/3213-005 03/13/95 APPLICABLE MODEL: FT3013/3213 SUBJECT: 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 •...

  • Page 369: Units Affected

    TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 006 10/26/95 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT3013/3213 Parts Catalogs. This information sh ould be incorporated into all existing FT3013/3213 Parts Catalog documentation. Scanner Drive Motor Bracket •...

  • Page 370: Field Service Manual - Insert

    TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 007 10/26/95 APPLICABLE MODEL: FT3013/3213 SUBJECT: USER-CODE (U-O) SYMPTOM: User Code U-O is displayed at power up. CAUSE: The first scanner may accidentally move away from its home position during transportation/re-locatio n of the machine.
  • Page 371 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 008 1/26/96 APPLICABLE MODEL: FT3013/3213 SUBJECT: ENERGY STAR MODIFICATION (DETAILS) GENERAL: To conserve energy, the copier automatically turns "OFF" 30 minutes after the last copy job has been completed. The details of the machine operation are as follows: •...
  • 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 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 009 1/26/96 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following modifications have been made to comply with the Energy Star requirements discussed in Publications Bulletin #PUB-066. This information should be incorporated into all existing Parts Cata log documentation.
  • Page 375 Tech Service Bulletin No. 3013/3213 - 009 Page 2 of 3 3. The Main Switch Bracket has been added to secure the new main switch. The cover switch decal has been added to cover the symbol for the old main switch. Main Switch Decal - Cover Switch Bracket...
  • Page 376 Tech Service Bulletin No. 3013/3213 - 009 Page 3 of 3 REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM 12041576 A1525220 Main Switch A1521343 Main Switch Bracket A1515100 A1515106 Main Control Board (FT3013) A1525100 A1525106 Main Control Board (FT3213) A1525105 A1525108 IC512 X 8 150NS D (FT3213)
  • Page 377 ORDERING PROCEDURE: Ricoh Corporation will automatically ship one replacement ROM for each unit shipped based on Ricoh’s Equipment Shipped Records. Those units still in Ricoh inventory will be shipped with a new ROM Kit to be installed upon machine setup.
  • Page 378 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 011 09/04/96 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The following Parts Catalog Correct is being issued for all FT3013/3213 Parts Catalogs. This informa tion should be incorporated into all existing Parts Catalog documentation. REFERENCE INCORRECT CORRECT...
  • Page 379 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 012 03/13/97 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The following Parts Catalog Correction is being issued for all FT3013/3213 Parts Catalogs. This info rmation should be incorporated into all existing Parts Catalog documentation. Please correct your Parts Catalog as follows.
  • Page 380 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213 - 013 05/06/97 APPLICABLE MODEL: FT3013/3213 SUBJECT: PARTS CATALOG CORRECTION GENERAL: Correct the Part Number and Description of item #3 as shown below. This information should be incorporated into all existing FT3013/3213 Parts Catalog documentation. INCORRECT REFERENCE PART NUMBER...
  • Page 381 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213/3513/3713 - 014 7/29/97 APPLICABLE MODEL: FT3513/3713 SUBJECT: SERVICE MANUAL - INSERT GENERAL: The Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin p ackage contains 1 set of replacement pages. PAGES: ⇒...
  • Page 382 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213/3513/3713 - 015 7/29/97 APPLICABLE MODEL: FT3513/3713 SUBJECT: PARTS CATALOG CORRECTIONS GENERAL: The following Parts Catalog corrections are being issued for all FT3513/3713 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. 1.

  • Page 383: Description

    Tech Service Bulletin No. 3013/3213/3513/3713 - 015 Page 2 of 2 3. Change the following item into Bold letters as it is a PM part REFERENCE PART NUMBER DESCRIPTION PAGE ITEM A0779521 Separation Corona Wire - 10 pcs/set 4. Add the following to your PM parts index Section Name Part Number Description...
  • Page 384 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 3013/3213/3513/3713 - 016 11/17/97 APPLICABLE MODEL: FT3513/3713 SUBJECT: SOFTWARE MODIFICATION SYMPTOM: 1. E54 is indicated after warm-up, usually seconds after the Fusing Lamp has turned off at 185°C. This occurs only on the machines that have Fusing Phase Control Mode turned ON. 2.
  • Page 385 ORDERING PROCEDURE: To obtain the ROM at no charge, please complete and fax the attached form to Technical Services or download a Hex file for local programming via the Ricoh Technical Services BBS (refer to Service News and Information No.147) Fax this entire page in "DETAIL"...
  • Page 386 8)',2-'%0#7)6:-')#&900)8-2 '97831)6#7)6:-')#+6394 &900)8-2#291&)6U GNEGfGFEGfGIEGfGKEG#h#NEK#####################################NGfEKfML %440-'%&0)#13()0U *8GNEGfGFEGfGIEGfGKEG SUBJECT: FEED MYLAR GENERAL: We have made corrections on Page 16 ∼17 of the Parts Catalog . Please correct your Parts Catalog as follows: 1) Item No. 3, of the illustration on page 16 is the Feed Mylar and has the incorrect item number. The correct item number for the Feed Mylar should be 13.
  • Page 387 Tech Service Bulletin No. 3013/3213/3513/3713– 017 Page 2 of 2 Note: The three Bulletins that were issued for the 3513/3713 series and were numbered 001, 002, 003, should have been released under the 3013/3213/3513/3713 series. Because of this oversight they have been renumbered as : Date 3013/3213/3513/3713 –...
  • Page 388 TECHNICAL BULLETINS BULLETINS Click on the Directory you wish to view.
  • Page 389 8)',2-'%0#7)6:-')#&900)8-2 &900)8-2#291&)6U %EIEf%EIFf%FNFf%FNG#g#NNE NIfFNfML %440-'%&0)#13()0U The chart listed below shows the Last Bulletin ####+)78)82)6#h#FKEGfFKEG> Number issued for the A151/A152/A202/A203 series. ####6-'3,#h#*8GIEGfGKEG Bulletin Cross Reference Ricoh Group Companies Last Bulletin No. ####7%:-2#h#MEEGfMEEG> Gestetner Ricoh Savin 9113 SUBJECT: TERMINAL HOLDERS Savin 9013 GENERAL: The part numbers for the Terminal Holders were omitted from the original Parts Catalog.
  • Page 390 The following parts updates are being issued for all A202 and A203 Parts Catalogs. REFERENCE PART NO. DESCRIPTION OLD SUFFIX NEW SUFFIX PAGE ITEM A2025108 IC – UVEPROM 512K x 8 (A202) A2035108 IC – UVEPROM 512K x 8 (A203) Continued… '328630#23T#FLM RICOH GROUP COMPANIES...
  • Page 391 Tech Service Bulletin No. A151/A152/A202/A203 – 002 Page 2 of 2 The Main Board ROM (A202) revision E (file name 3513M1.EXE) can be downloaded through the Ricoh Technical Services BBS. The Main Board ROM (A203) revision F (file name 3713M2.EXE) can be downloaded through the Ricoh Technical Services BBS.
  • Page 392 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) RICOH GROUP COMPANIES CONTROL NO. 304...
  • Page 393 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.

  • Page 394: Reference

    UNITS AFFECTED: All copiers manufactured after the Serial Numbers listed below will have the new style Upper Cover installed during production. MODEL NAME SERIAL NUMBER Savin 9113 7A98870104 Savin 9113Z 8A18860001Cover 8A18870001 Decal RICOH GROUP COMPANIES CONTROL NO. 312...
  • Page 395 NEW parts CAN NOT be used in OLD machines. Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or previously modified, use the new part numbers individually. CONTROL NO. 351 RICOH GROUP COMPANIES...
  • Page 396 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: A151/A152/A202/A203 - 007 09/07/99 APPLICABLE MODEL: GESTETNER – 2713/2713Z RICOH – FT3513/3713 SAVIN – 9113/9113Z SUBJECT: MAIN SWITCH GENERAL: The following part correction is being issued for all A202 and A203 Parts Catalogs. Please update your Parts Catalogs with the following information.
  • Page 397 The following part correction is being issued for all A202/A203 Parts Catalogs. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM A2031166 A2031165 Bottle Drive Motor     2000 RICOH Corporation. All rights reserved. CONTROL NO. 031ABW...

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