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A202/A203 COPIER SERVICE MANUAL
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 service manual regarding the other information.
24 February 1997
SPECIFICATIONS
NOTE: Only items marked with V are different from A151 and A152 copiers. Configuration: Copy Process: Original Type: Original Alignment: Original Size: Copy Paper Size: Desk top Dry electrostatic transfer system Sheet/Book Left center Maximum: A3/11" x 17" (lengthwise) - A203 copier B4/10" x 14" (lengthwise) - A202 copier Maximum: B4/10" x 14" (lengthwise) Minimum: Paper Tray: A5/51/2" x 81/2" (lengthwise) Bypass Feed: A6/51/2" x 81/2" (lengthwise) Paper tray feed -- 64 to 90 g/m2 (17 to 24 lb) Bypass feed -- 52 to 105 g/m2 (14 to 28 lb) 2 Enlargement and 3 Reduction (A203 copier only)
A4 Version 141% 122% 100% 93% 82% 71% Letter Version 129% 121% 100% 93% 74% 65%
Copy Paper Weight: Reproduction Ratios:
Enlargement Full size Reduction
Zoom: Copying Speed: Warm-up Time: First Copy Time: Copy Number Input: Manual Image Density Selection:
From 61% to 141% in 1% steps (A203 copier only) 13 copies/minute (A4/81/2" x 11" lengthwise) 10 copies/minute (B4/81/2" x 14") 30 seconds (at 20°C/68°F) 9 seconds (A4/81/2" x 11" lengthwise) Number keys, 1 to 99 7 steps
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A202/A203 Copier
1. SPECIFICATIONS
SPECIFICATIONS
24 February 1997
Automatic Reset: Energy Saver Function: Paper Capacity:
1 minute standard setting; can also be set to 3 minutes or no automatic reset. Automatic Paper tray -- 250 sheets or less than 28 mm stack height Bypass feed table -- 1 sheet Cartridge exchange (320 g/cartridge) 100 sheets (B4/10" x 14" or smaller) 1 sheet (OPC) 110 V/60 Hz/15 A (for Taiwan) 120 V/60 Hz/15 A (for North America) 220 V ~ 240 V/50 Hz/8 A (for Europe) 220 V/50 Hz/8 A (for Middle East) 220 V/60 Hz/8 A (for Saudi Arabia) 220 V/50 Hz/8 A (for Asia) Refer to the serial number plate (rating plate) to determine the power source required by the machine.
Copier Only 1.4 kVA 620 VA (average) 810 VA (average) 160 VA (average) With DF 1.5 kVA 640 VA (average) 860 VA (average) 180 VA (average)
Toner Replenishment: Copy Tray Capacity:
V Power Source:
Power Consumption:
Maximum Warm-up Copy cycle Ready
V Noise Emission:
Sound power level (The measurements are made in accordance with ISO 7779.)
Copy cycle Stand by Copier Only Less than 64 dB Less than 55 db Copier with document feeder Less than 62 dB Less than 40 dB
Sound pressure level (The measurements are made in accordance with ISO 7779 at the operator position.)
Copy cycle Copier Only Less than 58 dB Copier with document feeder Less than 62 dB
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24 February 1997
SPECIFICATIONS
Width Copier with platen cover and copy tray Copier with document feeder and copy tray 713 mm (28.1") 713 mm (28.1")
Depth 592 mm (23.3") 592 mm (23.3")
Height 400 mm (15.7") 463 mm (18.2")
Weight: Optional Equipment: (Sales items) Optional Equipment: (Service items)
·
Copier only: 43 kg (94.8 lb) With DF: 50 kg (110.2 lb) Document feeder (A203 copier only) Key counter Drum anti-condensation heater Optics anti-condensation heater Pre-transfer lamp
Specifications are subject to change without notice.
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A202/A203 Copier
Dimensions:
COPY PROCESS CONTROL
24 February 1997
2. COPY PROCESS CONTROL
· ·
Drum residual voltage (VR) correction and detection have been eliminated. Drum wear correction has been eliminated.
Grid Voltage Exposure Lamp Voltage Base exposure lamp voltage (Manual or ADS mode) (SP48) Development Bias Voltage Base bias voltage factor (Manual or ADS mode) (SP34) Erase Lamp Depends on paper size and reproduction ratio
Image Density Control
Standard image density grid voltage (--680 V) + Auto image density level factor (SP34)
+ VL correction factor + Reproduction ratio correction factor (A203 copier only)
+ Image bias voltage adjustment factor (SP37) + Note: Base bias voltage at manual ID level 7 can be adjusted with SP50 Depends on ID sensor bias setting (SP33) Note: For the initial 499 copies, bias voltage is increased by --20 volts ID sensor pattern erase (Vsg detection: Full erase)
Toner Standard ID sensor Density grid voltage Detection (--460 V)
Same as image density control
Between 0 Volts (Fixed) Copies
Exposure lamp turns --160 Volts (Fixed) off + Image bias voltage adjustment factor (SP37)
Full erase (All LEDs ON)
NOTE: The boxed items can be adjusted by SP mode.
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24 February 1997
MECHANICAL COMPONENT LAYOUT
NOTE: Only items marked with V are different from A151 and A152 copiers.
16 17
18 19 20
21
22 23
24
25
26 27 28 29 30
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
A203V500.img
31 32
33
1. Semicircular Feed Rollers 2. Paper Tray 3. Registration Rollers 4. Transfer and Separation Corona Unit 5. Pick-off Pawl 6. Cleaning Unit 7. Pressure Roller 8. Fusing Unit 9. Hot Roller 10. Exit Rollers
11. Copy Tray 12. Hot Roller Strippers 13. Exhaust Blower Motor 14. 3rd Mirror 15. 2nd Mirror 16. 1st Mirror 17. Ozone Filter 18. Used Toner Tank 19. Cleaning Blade 20. Quenching Lamp 21. Charge Corona Unit 22. Lens
23. 6th Mirror 24. Erase Lamp 25. Drum 26. 4th Mirror 27. 5th Mirror V 28. Optics Cooling Fan Motor (in A202 & A203) 29. Toner Supply Unit 30. Development Unit 31. 2nd Relay Rollers 32. By-pass Feed Table 33. 1st Relay Rollers
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A202/A203 Copier
3. MECHANICAL COMPONENT LAYOUT
ELECTRICAL COMPONENT LAYOUT
24 February 1997
4. ELECTRICAL COMPONENT LAYOUT
NOTE: Only items marked with V are different from A151 and A152 copiers. 23 24 22 25 21 26 20 27 19 29 18 30 31 17 16 15 32 14 33 13 34 12 11 10
9
8
7
6
36 5 37 4 38 3 2 1
35
A203V501.img
1. Paper Tray Switch 2. Relay Sensor 3. Registration Clutch V 4. Optics Cooling Fan Motor 5. Registration Sensor 6. Image Density Sensor 7. Power Pack-TC/SC 8. Operation Panel Board 9. Erase Lamp 10. Total Counter 11. Quenching Lamp 12. Fusing Lamp 13. Front Cover Safety Switch 14. Main Switch 15. Fusing Thermoswitch
16. Exit Sensor 17. Exhaust Blower Motor V 18. Optics Thermofuse 19. Auto Image Density Sensor 20. Fusing Thermistor 21. Exposure Lamp 22. Lens Motor (A203 copier only) 23. Scanner Home Position Sensor 24. Optics Thermistor V 25. Lens Home Position Sensor (A203 copier only) 26. Power Pack-CC/Grid/Bias
27. AC Drive Board 28. N/A 29. Scanner Motor 30. 4th/5th Mirror Home Position Sensor (A203 copier only) 31. 4th/5th Mirror Motor (A203 copier only) 32. Main Motor Capacitor 33. Main Board 34. Main Motor 35. Toner Supply Motor 36. DC Power Supply Board 37. Relay Roller Clutch 38. Paper Feed Clutch
NOTE: Index No. 28 is not applicable for this model.
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ELECTRICAL COMPONENT DESCRIPTIONS
The following motor is included as an electrical component.
Symbol M7 Name Toner Supply Motor Function Drives the toner supply roller. Index No. 35
The following clutch and triac are not included in this copier.
Symbol MSC1 TR Name Toner Supply Clutch Fusing Triac (115 V only) Function Drives the toner supply roller. Switches the fusing lamp on and off. Index No. 35 28
The following part has been changed.
Symbol Name Quenching Lamp L3 Function Receives dc power from the main board (the lamp in the A151/A152 received ac power from the ac drive board). Index No.
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A202/A203 Copier
5. ELECTRICAL COMPONENT DESCRIPTIONS
DRIVE LAYOUT
24 February 1997
6. DRIVE LAYOUT
NOTE: Only items marked with V are different from A151 and A152 copiers.
V G13 V G14
G12 BP6 TB3 BP5 G11 G10 G23
G9 G15 G16 G17 G18 G19 G4 G3 TB1 G20 G21 G22 BP2 BP1 G1 G2
A203V502.img
G8 G7 G6 G5
BP4 BP3 G24
G26 G9 G25 TB2 G1
A203V503.img
G8 G2
G1: Main Motor Gear G23: Timing Belt Drive Gear BP1: Timing Belt Pulley TB1: Timing Belt G10: Relay Gear
G2: Relay Gear
G8: Relay Gear G11: Timing Belt Drive Gear G9: Relay Gear BP5: Timing Belt Pulley TB3: Timing Belt G3: Cleaning Unit G3: Fusing Drive Gear Fusing and Exit Unit G4: Hot Roller Gear G7: Relay Gear G6: Relay Gear
A203V504.wmf
B
A
Development Section BP6: Timing Belt Pulley G12: Development Gear Development Unit
G5: Exit Roller Gear
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24 February 1997
DRIVE LAYOUT
A
Paper Feed Section BP2: Timing Belt Pulley
B
G24: Timing Belt Drive Gear BP3: Timing Belt Pulley
G1: Registration CL Gear Registration CL Registration Rollers
G22: Relay Gear TB2: Timing Belt Paper Feed Section BP4: Timing Belt Pulley G25: Relay Gear
G20: Relay Gear G17: Relay Roller CL Gear Relay Roller CL G16: 2nd Relay Roller Gear 2nd Relay Rollers G19: 1st Relay Rollers Gear 1st Relay Rollers
G21: Paper Feed CL Gear G26: Drum Drive Gear Paper Feed CL Feed Rollers
V G13: Toner Supply Motor Gear V G14: Toner Supply Gear V
Toner Supply Unit
A203V505.wmf
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A202/A203 Copier
POWER DISTRIBUTION
24 February 1997
7. POWER DISTRIBUTION
NOTE: Only items marked with V are different from A151 and A152 copiers.
AC Power (115V or 220V ~ 240V) Main SW Anti-condensation Heaters -Drum (Option) -Optics (Option) Scan Signal Sensors Power Relay (RA401) 24V (VA) 5V (VC)
Cover Safety SW 5V
Operation Panel Board
Thermistors Fusing Lamp Drive Circuit Fusing Lamp Exposure Lamp Drive Circuit Exposure Lamp 24V (VA) Relay (RA402) Main Motor AC Drive Board Document Feeder (Option)
V Toner Supply Motor V Quenching Lamp
24V (VA) RAM Pack 24V (VA) Main Board
Solenoids Clutches Power Packs Lens Motor (A203 copier only) 24V (VA) 4th/5th Mirror Motor (A203 copier only) V Optics Cooling Fan Motor
AC power DC power
DC Power Supply Board
24V (VA) 5V (VC) Zero Cross
5V (VC) 24V (VA)
Scanner Motor
A203D500.wmf
When this copier is plugged in and the main switch is turned off, ac power is supplied via the ac drive board to the optional anti-condensation heaters. When the front cover and/or the exit cover is open, the cover safety switch completely cuts off power to all ac and dc components. When the main switch is turned on, the ac power supply to the anti-condensation heater is cut off and ac power is supplied to the ac drive board. The dc power supply board receives wall outlet ac power through the ac drive board. The dc power supply board converts the wall outlet ac power input to +5 volts, +24 volts, and a zero cross signal, all of which are supplied to the main board.
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24 February 1997
POWER DISTRIBUTION
All other dc components, including the power relay (RA401) and the main motor relay (RA402), operate on +24 volts. When the main board receives power, it activates the power relay (RA401), which then supplies ac power to the fusing lamp drive circuit and the exposure lamp drive circuit on the ac drive board. The fusing lamp drive circuit receives a trigger signal from the main board and the fusing lamp lights. The exposure lamp does not turn on until the main board sends a trigger pulse to the exposure lamp drive circuit. When the key is pressed, the main board energizes the main motor relay (RA402). Then, the main motor turns on. When the main switch is turned off, power to the main board and to RA401 is cut off, and the optional drum and optics anti-condensation heaters are turned on.
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A202/A203 Copier
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.
DRUM CHARGE
24 February 1997
8. DRUM CHARGE
8.1 GRID VOLTAGE CORRECTION
This machine does not correct drum residual voltage correction (VR 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. As the grid voltage for the image density control becomes less, the copy image becomes lighter, and vice versa. The grid voltage for image density is based as follows: Grid Voltage = Standard image density grid voltage (--680 volts [SP60 = 4]) + Auto image density level factor (SP34) 8.2.1 Standard Image Density Grid Voltage The standard image density grid voltage (SP60) is set at the factory and the setting is different for each machine. The setting of SP60 is printed on the SP mode data sheet located inside the inner cover of the machine. 8.2.2 Auto Image Density Level Factor (SP34)
Auto image density level Normal Darker Lighter Data (SP34) 0* 1 2 Change of grid voltage (volts) ±0 --40 ±0 * Factory setting
The grid voltage and the exposure lamp voltage are constant regardless of the output from the auto image density sensor. Only the development bias voltage varies depending on the output from the auto image density sensor. When the auto image density level data in SP34 is set to darker, the grid voltage is changed --40 volts as shown in the above table. When it is set to lighter, the grid voltage does not change. However, the development bias voltage is corrected.
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24 February 1997
DRUM CHARGE
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. The setting of SP62 is printed on the SP mode data sheet located inside the inner cover of the machine.
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A202/A203 Copier
8.3 GRID VOLTAGE FOR TONER DENSITY DETECTION
OPTICS
24 February 1997
9. OPTICS
9.1 LENS POSITIONING
[C] [A] [B]
Home Position (100%)
I I
I
: Initialize (100% 141/129 %) (141/129% 71/65 %) (71/65% 93 %)
A203D501.img
[D]
I
(93% 71/65 %) (71/65% 141/129 %) (141/129% 122/121 %) (122/121% 100 %) (100% 71/65 %) (71/65% 100 %) Reduction Side
I I
I
Enlargement Side
A203D502.wmf
The lens home position sensor [A] informs the main board when the lens is at the full size position (home position). The main board determines the lens stop position in reduction and enlargement modes by counting the number of steps the motor makes with reference to the lens home position. When a new reproduction ratio is selected, the lens [B] moves directly to the selected magnification position. The lens home position is registered each time the lens starts from or passes through the lens home position sensor. As the lens moves from the enlargement side to the reduction side, the sensor registers the home position. This occurs when the actuator plate [C] enters the lens home position sensor. A small vibration can be observed when the lens moves through home position from the enlargement side to the reduction side because the lens is going in the wrong direction to register the home position. The lens overshoots the home position by four pulses before going back to register the home position. The lens always stops while moving from left to right (as viewed from the front) to minimize the error caused by mechanical play in the drive gears [D].
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24 February 1997
OPTICS
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 A151 and A152 copiers at the indicated locations.
A203D503.wmf
A203D504.wmf
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A202/A203 Copier
9.2 BASE LAMP VOLTAGE IN MANUAL IMAGE DENSITY MODE
DEVELOPMENT
24 February 1997
10. DEVELOPMENT
10.1 DEVELOPMENT BIAS CIRCUIT
Charge Corona Power Pack CC/Grid/Bias (P1)
Bias Trig (PWM) [v00/5]
Grid
Development Bias
A203D505.wmf
A203D506.wmf
The main board supplies +24 volts to the CC/Grid/Bias power pack at CN1-1. key is pressed, the CPU starts sending the bias trigger pulses When the to CN1-4. This energizes the development bias circuit within the CC/Grid/Bias power pack, which applies a high negative voltage to the development roller. The development bias is applied whenever the drum is rotating. The bias trigger pulse applied to CN1-4 is a pulse width modulated signal (PWM signal). The width of the pulses controls the voltage level of the development roller. As the width of the trigger pulses increase, the voltage to the development roller also increases. The power pack is equipped with its own feedback circuit to monitor the development bias voltage.
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24 February 1997
TONER DENSITY DETECTION AND TONER SUPPLY
11.1 ID Sensor Control Circuit
This circuit is different from A151 and A152 copiers at the indicated location.
A203D509.wmf
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A202/A203 Copier
11. TONER DENSITY DETECTION AND TONER SUPPLY
TONER DENSITY DETECTION AND TONER SUPPLY
24 February 1997
11.2 TONER SUPPLY AND AGITATOR DRIVE MECHANISM
[C] [B]
[A]
A203D508.wmf
[D] [F]
[H]
[G]
[E]
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]. Then, as the grooves turn past the pin hole plate [E], the toner drops into the development unit through the pin holes. The toner agitator [F] mechanism, which is contained in the toner cartridge, prevents toner from clumping. The toner agitator gear [G] turns whenever the toner supply motor energizes. Rotation passes through the toner cartridge casing to the agitator junction [H].
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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. This is performed during every first copy. 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.
Paper length (mm) 364 356 330 297 279 267 257 254 216 210 Paper size B4 10" x 14" 81/2" x 13" A4R 81/2" x 11" 8" x 101/2" B5R 8" x 10" 51/2" x 81/2" A5R
Since the CPU does not have the paper length in memory for the first copy cycle, the CPU controls the machine for the maximum paper size of B4 (257 mm x 364 mm). From the second copy cycle on, the CPU controls the machine for the correct paper size based on the data stored during the first paper cycle. Whenever the by-pass feed table is used, the CPU determines the paper size to be B4 (257 mm x 364 mm).
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A202/A203 Copier
12. PAPER FEED
IMAGE FUSING
24 February 1997
13. IMAGE FUSING
13.1 FUSING LAMP CONTROL CIRCUIT
The circuit of the main board is different from A151 and A152 copiers at the indicated location.
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; therefore, Q101 stays on, allowing PC402 to operate. If the hot roller temperature reaches 240°C, the resistance of the thermistor becomes too low. At that time, pin 1 of IC120 becomes HIGH, turning off Q101 and stopping PC402. At the same time "E53" lights on the operation panel and the power relay (RA401) turns off. Even if the thermistor overheat protection fails, a thermoswitch installed in series with the fusing lamp prevents the fusing unit from excessive overheating. If the thermoswitch temperature reaches 170°C, the thermoswitch opens, removing power from the fusing lamp.
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24 February 1997
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. Installation Procedure - Multi-language (-10, -15, -22, -26, -50 machines) 5. Operation Instructions - English (-10, -15, -17, -22, -26, -28, -29 machines) 6. Operation Instructions - Chinese (-19, -50 machines) 7. NECR - English (-17 machines) 8. NECR - Multi-language (-19, -27, -28, -29 machines) 9. Copy Tray 10. User Survey Card (-17 machines)
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A202/A203 Copier
14. INSTALLATION
INSTALLATION
24 February 1997
14.2 COPIER (A202/A203) INSTALLATION PROCEDURE
A203I500.wmf
[B]
[A]
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.
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24 February 1997
INSTALLATION
[B]
A202/A203 Copier
[A] [F]
[F] [C]
A203I502.img
[E] [G] [H] [I] [D]
A203I503.img
[K]
[J]
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. 4. Open the front cover [C], and remove the foam block [D]. 5. Remove the shipping retainer [E] and seals [F]. NOTE: Save the shipping retainer for future shipping. 6. Open the upper unit [G] by pressing the release lever [H]. Gently remove the shipping spacers [I] from the transfer/separation corona unit [J]. Remove the strip of tape [K] and close the upper unit.
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INSTALLATION
24 February 1997
[C] [A]
[B] [D]
A203I505.img A203I506.img
[F]
[E]
[G]
A203I508.img
A203I507.img
7. Pull out the development unit [A] while pulling the left side of the development cover [B] (2 screws), and place it on a clean sheet of paper. 8. Remove the toner supply unit [C] from the development unit [D] (2 screws). 9. Shake one pack of developer [E] well, and pour it into the development unit, while rotating the gears [F] on both sides to distribute the developer evenly as shown in the illustration. 10. Reinstall the toner supply unit on the development unit. NOTE: Make sure that there is no gap [G] between the toner supply unit and the development unit. (See the illustration.)
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24 February 1997
INSTALLATION
[B] [A]
A203I509.img
[A]
A203I510.img
11. Reinstall the development unit. 12. Shake a toner cartridge [A] well and slide it into the machine, while pulling off the seal [B]. Then, complete installing the cartridge as shown. 13. Close the front cover.
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A202/A203 Copier
INSTALLATION
24 February 1997
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. c) Release the d) Press the key and again press the key again.
key, then input 65 with the number keys.
3) Operate SP 65 as follows.
SP Mode Number Developer Initial Setting 65 Procedure Enter "65" using the number keys and press the key. "50" will be displayed in the copy counter. Press the key to start the initial setting. It takes about 5 minutes.
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24 February 1997
INSTALLATION
[A]
[B]
A203I511.wmf
A203I512.wmf
[C]
A203I513.wmf
[E] [D]
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. Load paper into the paper tray [D] as explained in the instructions written on the paper tray. 18. Change the paper size plate [E] to display the correct paper size. 19. Check the machine operation and copy quality.
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A202/A203 Copier
[A]
INSTALLATION
24 February 1997
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. NECR - Multi-language..................................................... 1 6. Interface Unit for A219 copier .......................................... 1 7. Accessory Kit for A203 copier .......................................... 1 · Interface Unit Bracket.................................................. 1
· · · · · · · ·
Stud Screw (M4) ......................................................... 2 Harness Clamp ........................................................... 1 Upper Unit Stand......................................................... 1 Stepped Screw (Short)................................................ 1 Stepped Screw (Long) ................................................ 1 Magnet ........................................................................ 1 Operation Decal .......................................................... 1 Screw Driver................................................................ 1
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24 February 1997
INSTALLATION
[B]
[A] [F] 230 ~ 240 V [C] [D] 220 ~ 230 V
[E]
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. Replace the 2 screws with the 2 stud screws [B].
· Use the M4 stud screws.
3. Remove the strips of tape from the DF. CAUTION The next step (step 4) must be done only in 240 volt areas. 4. Perform the conversion from 220 230 V to 240 V as follows: 1) Remove the main board cover [C] (2 screws). 2) Disconnect the connector for 220 230 V [D] (Black Wire) from the ac harness connector [E] and connect the connector for 240 V [F] (White Wire) to the ac harness connector. 3) Reinstall the cover.
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A202/A203 Copier
14.4 DOCUMENT FEEDER (A662) INSTALLATION PROCEDURE
INSTALLATION
24 February 1997
[A]
[C]
[B]
[E]
A662I506.img
[G] [F]
[D]
A662I507.img
[H]
[I]
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. Remove the interface harness [F] (3 screws) and the interface board with 2 locking supports [G] from the A219 interface unit bracket [H]. 10. Attach the interface board and the interface harness to the A203 interface unit bracket [I] (3 screws).
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24 February 1997
INSTALLATION
[A] [B] [E]
[C]
[D]
A662I508.img
[F] [G]
A662I509.img
11. Locate the 4P connector [A] and connect it to the ADF interface board [B], 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. Plug the connector [D] (3P/Black) into CN418 on the ac drive board [E] as shown. 13. Reinstall the upper rear cover. 14. Plug the optics fiber cable [F] into the DF and the copier as shown. 15. Plug the DF power supply cord [G] into the outlet in the rear of the copier as shown. 16. Open the front cover. 17. Lift up the upper unit.
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A202/A203 Copier
INSTALLATION
24 February 1997
[D]
[A] [A] [B]
A662I510.img
[C]
[E]
A662I511.img
[F]
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. Close the upper unit and the front cover. 24. Instruct key operators how to use the upper unit stand.
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24 February 1997
INSTALLATION
[E]
A202/A203 Copier
[C]
[D]
A662I514.img
[E]
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. 26. Turn on the main switch and check the operation of the DF.
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SERVICE PROGRAM MODE
24 February 1997
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. 4. Press the key again and then press the key.
NOTE: "5" will blink in the Copy Counter to show that the SP mode has been accessed. 5. Enter the desired SP mode number using the number keys. The SP mode numbers are given in the Service Program Mode Table. NOTE: "1" is displayed in the Manual ID indicator (as shown below) instead of "1" in the Copy Counter when SP mode numbers over "100" are entered. The maximum number is "111". : "1"
A203M500.wmf
6. Press the
key to view the current setting. key.
NOTE: To enter a different SP mode number, press the
7. To leave SP mode, open and close the front cover or turn the main switch off and on.
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24 February 1997
SERVICE PROGRAM MODE
-- 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 SP111: Total Service Calls
1. Enter SP mode. 2. Enter "98" with the number keys, then press the current setting. 3. Enter "1" using the number keys, then press the same time. key to view the and keys at the
NOTE: The Manual Image Density indicator blinks when the above procedure is completed. 4. Turn off the main switch.
35
A202/A203 Copier
15.2 MEMORY CLEAR PROCEDURE
SERVICE PROGRAM MODE
24 February 1997
15.3 CLEAR ALL MEMORY PROCEDURE
CAUTION: The Clear All Memory procedure (SP99) resets all the correction data for copy process control and all the software counters, and returns all modes and adjustments to the default settings. Normally, this SP mode should not be performed. This procedure is required only when replacing the EEPROM or when the copier malfunctions due to a damaged EEPROM. 1. Enter SP mode. 2. Enter "99" with the number keys, then press the current setting. 3. Enter "1" with the number keys, then press the same time. key to view the and keys at the
NOTE: The Manual Image Density indicator blinks when the above procedure is completed. 4. Clean the used toner tank, since the toner end counter has been cleared. (See Used Toner Removal in the A151/A152 Service Manual.) CAUTION: Skipping this step will cause the used toner overflow condition not to be detected properly. 5. Replace the OPC drum with a new one. (See Drum Replacement in the A151/A152 Service Manual.) CAUTION: Since the drum motor rotation time (SP57) for the drum wear correction has been cleared, the old drum cannot be used. If the old drum is used after all memory is cleared, dirty background may occur. 6. 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 applied to the development roller for the initial 499 copies. 7. Clean the optics, sensors, and inside of the copier if necessary. 8. 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
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24 February 1997
SERVICE PROGRAM MODE
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) 10. Turn off the main switch.
37
A202/A203 Copier
9. Perform the following SP modes in sequence: 1) SP66: Drum Initial Setting
SERVICE PROGRAM MODE
24 February 1997
15.4 SERVICE PROGRAM MODE TABLE
1. Only items marked with V are different from A151 and A152 copiers. 2. A "" after the mode name means that copies can be made while in the SP mode. (Copies can be made by pressing the key after pressing the key.) 3. In the Function column, comments (extra information) are in italics. 4. In the Settings column, the default value is printed in bold letters. 5. For some SP modes, display of the settings is different between the A202 and A203 models because of the difference in the operation panel. After entering the desired SP mode number, refer to the notes written at the end of the table to correctly observe the displayed setting. (Which note to refer is described inside the Function column.)
Mode No. Function Settings Free Run with key to Turn on DPS101-1, then press the Exposure Lamp start the free run. Press the key to stop the OFF key in Ready mode to free run. Press the 5 turn off this mode. Use this mode for the scanner movement check. To save toner, remove the development unit. Misfeed Copies are made without misfeed detection. Detection Off Press the key to make a copy. Press the key in Ready mode to turn off this mode. 6 Use this mode to check whether a paper misfeed was caused by a sensor malfunction. The total counter increments when copies are made in this mode. 7 Aging Mode Factory use. Input Check Displays the inputs from sensors and switches. For details, see 8 page 46. Output Check Turns on electrical components. For details, see 9 page 47. All Indicators ON Turns on all the indicators on the operation panel. 11 To turn off the indicators, press the key. Auto Reset Select the auto shut off time. 0: 30 min. Time Setting The copier main switch is shut off automatically 1: 15 min. 14 (Energy Star) after the selected auto shut off time, if SP77 is at 2: 60 min. "0". 3: 90 min. 4: 120 min. 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. 15 Saver Mode) 2: None The copier automatically goes to the energy saver mode at the selected reset time if SP78 is at "1".
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SERVICE PROGRAM MODE
16
17 Open Key Function 18 (A203 copier only) ADS Priority 19 SADF Shut off V Time (A203 22 copier only) Fusing Temperature 29 Control Toner Supply Mode
No function. Specifies whether reduction or enlargement is selected first when the key is pressed. Specifies whether the copier defaults to ADS or manual mode when the main switch is turned on. Selects the shut off time for SADF mode. The DF must be installed on the machine. Selects the fusing temperature control mode. After selecting the control mode and turning the main switch off/on, the fusing temperature control mode is changed. Selects the toner supply system. See SP31/SP32 for the toner supply amount. Determines how much toner is supplied in detect mode.
0: Reduction 1: Enlargement 0: ADS 1: Manual 0: 5 s 1: 60 s 0: ON/OFF control 1: Phase control 0: Detect Mode 1: Fixed Mode
30
Toner Supply Ratio 31 (Detect Mode) Toner Supply Ratio 32 (Fixed Mode) ID Sensor Bias 33
ADS Level
34
35
ID Detection Interval
0: 15% 1: 7% 2: 30% 3: 60% Determines how much toner is supplied in fixed 0: 7.0% mode. 1: 3.5% 2: 10.5% 3: 14.0% Sets the bias voltage applied to the development Toner Density roller for the ID Sensor Pattern. 0: Normal (Vo) 1: Low 0: Vo 2: High 1: Vo+40 V 3: Higher 2: Vo--20 V 3: Vo--40 V Selects the image density level in ADS mode. 0: Normal 1: Darker setting: 1 2: Lighter Increases grid voltage (--40 V). Development bias voltage is not changed. setting: 2 Increases development bias voltage (--40 V). Grid voltage is not changed. ID sensor check is performed every 5 copies or 0: 10 copies 10 copies. 1: 5 copies If low image density occurs in the near end condition, change the setting to "1".
39
A202/A203 Copier
Mode No. Function Count Up/Down Selects count up or count down.
Settings 0: Up 1: Down
SERVICE PROGRAM MODE
24 February 1997
Mode No. Image Bias Adjustment 37
Lead Edge 41 Erase Margin Adjustment 42 Registration Adjustment
Function Adjusts image bias output if the image density at level 4 cannot be adjusted by the Light Intensity adjustment (SP48). 0: Vo 1: Vo+40 V 2: Vo+20 V 3: Vo--20 V 4: Vo--40 V Adjusts the lead edge erase margin. 0.4 mm per step. (--3.2 mm to +2.8 mm)
Settings 0: Normal (Vo) 1: Darkest 2: Darker 3: Lighter 4: Lightest
0 ~ 15 Default = 8
Vertical 43 Magnification Adjustment Horizontal Magnification 44 Adjustment (A203 copier only) Registration 45 Buckle -- Paper Feed Focus Adjustment 47 (A203 copier only) Light Intensity Adjustment 48
Adjusts registration. 0 ~ 15 Default = 8 0.4 mm per step. (+3.2 mm to --2.8 mm) Adjusts magnification in the paper travel direction.0 ~ 15 Default = 8 0.2% per step. (--1.6% to +1.4%) Adjusts magnification perpendicular to the direction of paper travel. 0.2% per step. (--1.6% to +8.4%) 0 ~ 50 Default = 8
Fusing 49 Temperature Adjustment Image Bias Adjustment at 50 ID Level 7
Adjust the amount of paper buckle in the registration area. 0.4 mm per step. (--3.2 mm to +2.8 mm) Adjusts the 4th/5th mirror position to correct focus. This mode must be done after horizontal and vertical magnification adjustment (SP43 and 44). Adjusts the exposure lamp voltage. Before performing this mode, clean the optics and perform SP95. After performing this mode, perform SP56. The exposure lamp voltage is adjusted on the production line. Refer to NOTE 2 for the A202 copier. Adjusts the control temperature of the hot roller during copying in 1°C steps. Adjusts image bias voltage at ID level 7. 0: Vo 1: Vo+40 V 2: Vo--40 V 3: Vo--80 V
0 ~ 15 Default = 8 0 ~ 100 Default = 40
100 ~ 170 Default = 126
175°C ~ 200°C Default = 185°C 0: Normal (Vo) 1: Darker 2: Lighter 3: Lightest
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SERVICE PROGRAM MODE
Mode No. Function Exposure Lamp Displays the exposure lamp setting with a Setting Display reference number. The exposure lamp and optics cooling fans turn key is pressed. on for 10 seconds when the 51 Press the key to turn this mode off. Do not repeat more than 5 times, to avoid overheating the optics cavity. Refer to NOTE 2 for the A202 copier. Fusing Displays the fusing temperature. 52 Temperature Refer to NOTE 2 for the A202 copier. Display Displays Vsg. Adjust Vsg to 4.0 ± 0.2 V using VR102 on the 54 main board. The main motor and the ID sensor LED turn on when the key is pressed. Refer to NOTE 3 for the A202 copier. Vsg & Vsp Displays the Vsg and Vsp readings. Display The Vsg reading is displayed while the "0" key is held down. The A202 copier displays the Vsp reading while the "1" key is held down. In the A203 copier, Vsp is always displayed in the magnification indicator. To stop this mode, press 55 the key. The Vsp and Vsg voltage readings are updated every 10 or 5 copies depending on the SP35 selection. In free run mode, the Vsg and Vsp readings are updated every copy cycle. Refer to NOTE 3 for the A202 copier. ADS Reference Displays the ADS reference voltage. Voltage Display Before performing this mode, clean the optics, and Adjustment and perform SP95 and SP48. After adjusting the light intensity (SP48), place 5 56 sheets of A3 (LDG) white paper on the exposure glass and select this mode. Adjust the ADS voltage to 2.5 ± 0.1 V using VR101 on the main board. Refer to NOTE 3 for the A202 copier. Drum Rotation Displays the total time that the drum has rotated. 57 Time "Minutes" is displayed first. Press and hold the key to display "Hours". Toner End Displays the toner end condition counter. Counter The toner end counter counts up 1 after 200 58 copies are made following toner cartridge replacement. Optics Displays the optics temperature detected by the optics thermistor. V Temperature 59 Display Press the key to monitor the temperature during the normal copy cycle. Vsg Display/ Adjustment
41
A202/A203 Copier
Settings 100 ~ 150
SERVICE PROGRAM MODE
24 February 1997
Mode No. Function Standard Image Factory use only. 60 Grid Voltage Do not change the setting. Setting Refer to NOTE 5. Standard ID Factory use only. 62 Sensor Grid Do not change the setting. Voltage Setting Refer to NOTE 5. Toner Density Factory use only. 63 Level Setting Do not change the setting. Toner Density Displays the toner density level detected during Level Display initial setting (SP65). Setting Vsp/Vsg(%) 0: 12--15 64 1: 0--7 2: 8--11 3: 16--21 4: 22--100 Developer Initial Agitates new developer for about 5 minutes. Setting "50" is displayed in the copy counter when the key is held down. Press the key to start the initial setting. 65 Initial setting must be done when new developer is installed. The copier automatically returns to normal mode after initial setting is completed. Drum Initial Used to condition the new drum. Setting Initial setting must be done when a new drum 66 is installed. The Drum Rotation Time (SP57) and the OPC counter (SP69) are cleared. OPC Counter Shows the total number of copies made with the 69 drum installed in the machine. Refer to NOTE 4. VL Correction Selects or deselects VL correction. V Selection Keep this setting at 0. 71 Auto Shut Off (Energy Star) V On/Off 77 Selects the "Automatic Shut off" mode. The copier automatically shuts itself off at the auto shut off time selected (SP14).
Settings 0~8 Default = 4 0~8 Default = 4
0~4
0: No 1: Yes
0: VL correction 1: No VL correction 0: Yes (Default for N. America) 1: No (Default for other areas) 0: No 1: Yes
Auto Energy 78 Saver Mode
Selects the "Automatic Energy Saver" mode. The copier automatically goes to Energy Saver mode at the auto reset time selected (SP15).
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SERVICE PROGRAM MODE
Mode No. Function Horizontal Edge Selects whether the side erase mechanism Margin Width changes when the optional document feeder is V Adjustment installed. 80 Compared with the platen mode erase, the next inmost LED block will turn on to erase. V Factory Factory use only. 81 Initialization Do not change the setting. Toner End Clears the toner end counter (SP58). Resets the Counter Clear used toner overflow condition (E70) if it is 83 detected. This mode must be performed when the used toner tank is cleaned. Energy Saving Selects the energy saving ratio. Ratio The greater the saving ratio, the longer the waiting time until the copier returns to the ready condition. 86 Saving Ratio Waiting Time 0: 56% 25 s 1: 47% 19 s 2: 37% 12 s 3: 25% 5s VL Correction Resets the exposure lamp setting and counter Reset for the VL correction. 95 Before performing this mode, clean the optics parts. After performing this mode, perform SP48 and SP56. Toner End The Toner End condition is canceled forcibly. 96 Force Cancel By pressing the key to enter this SP mode, the toner end condition is canceled. Service Call Resets a service call (E5) condition. V (E5) Reset Turn the main switch off and on to check if the 97 service call condition is reset. Clear Counters Clear the following counters: V Copy counters V SC counters V Misfeed counters To clear, enter "1" then press the key and 98 the key at the same time. To avoid resetting the counter by mistake, the counter is reset only when the key and the key are pressed at the same time. Clear All Clear all counters and returns all modes to the Memory default settings. See the Clear All Memory Procedure in this section for more details. To clear, enter "1" then press the key and 99 the key at the same time. To avoid resetting the counter by mistake, the counter is reset only when the key and the key are pressed at the same time.
0: No 1: Yes
0: 56% 1: 47% 2: 37% 3: 25%
0: No 1: Yes
0: No 1: Yes
0: No 1: Yes
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A202/A203 Copier
Settings 0: Always stays in Platen Mode 1: DF Mode
SERVICE PROGRAM MODE
24 February 1997
Mode No. By-pass Feed 100 Copies Paper Tray 101 Copies 102 Open Total Copies 103 DF Originals 106 (A203 copier only) 110 111 Misfeeds (total) Total Service Calls
Function Displays the total number of copies fed from the by-pass feed table. Refer to NOTE 4. Displays the total number of copies fed from the paper tray. Refer to NOTE 4. No function. Displays the total number of copies. Refer to NOTE 4. Displays the total number of originals fed from the DF. Refer to NOTE 4. Displays the total number of paper misfeeds. Refer to NOTE 4. Displays the total number of times the service call indicator has turned on.
Settings
NOTE 1: 1) After the following SP mode numbers are entered, the copier goes automatically into copy mode when the Auto Image key is pressed: SP mode numbers: 5, 6, and 55 2) After the following SP mode numbers are entered and the key is pressed, select the desired input numbers or SP mode settings and press the key. SP mode numbers: 8, 37, 41, 42, 43, 44, 45, 47, 48, and 50 NOTE 2: 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 when the setting exceeds "99". : "1"
A203M500-2.wmf
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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"
: "4"
: "1"
: "5"
: "2" : "3.83 : "3"
Copy Counter
A203M501.wmf
NOTE 4: -- A202 copier -The A202 copier displays the SP mode setting in the Copy Counter. The first two digits are displayed first. Press the key once to display the next two digits and press the key one more time to display the last two digits (six digits in total). -- A203 copier -The first three digits are displayed in the Magnification Indicator. Press and hold the key to display the last three digits (six digits in total). NOTE 5: The setting will vary depending on the factory setting. Refer to the "FACTORY SETTING" table located in the upper inner cover.
45
A202/A203 Copier
SERVICE PROGRAM MODE
24 February 1997
15.5 SP MODE 8-INPUT CHECK
-- How to check sensor/switch inputs for the A202 copier -1. Enter "8" using the number keys, then press the key.
2. The Manual Image Density indicator is used to display the inputs from the following components. If you wish to see how the inputs behave during a copy cycle, press the key to perform this mode while making a normal copy.
Sensor Registration Exit Paper Tray Switch Relay Sensor Scanner HP Sensor Key Counter Set Signal Manual ID Level Indication ID Level 1 ID Level 2 ID Level 3 ID Level 4 ID Level 5 ID Level 6 ON: ON: ON: ON: ON: ON: Display: Condition Paper Present Paper Present Paper Tray Closed Home Position Actuator inside sensor Key Counter Set (Ready for Copying)
-- How to check sensor/switch inputs for the A203 copier -1. Enter "8" using the number keys, then press the Auto Image 2. Enter the desired number from the following table. 3. Press the key again. key.
4. Enter the number of copies and press the key. Either "0" or "1" is displayed in the Magnification Indicator.
No. 1 2 3 4 12 13 14 20 21 22 Sensor/Switch/Signal Registration Sensor Exit Sensor Paper Tray Switch Relay Sensor Scanner HP Sensor 4th/5th Mirror HP Sensor (A203 copier only) Lens HP Sensor (A203 copier only) ADF Installation ADF Lift Switch Key Counter Set Signal Display: Condition "0" "1" Paper not detected (HIGH) Paper detected (LOW) Paper tray opened (HIGH) Paper tray closed (LOW) Paper not detected (HIGH) Paper detected (LOW) Sensor not actuated (LOW) Sensor actuated (HIGH)
ADF not installed ADF closed Key Counter not set
ADF installed ADF opened Key Counter set
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24 February 1997
SERVICE PROGRAM MODE
-- How to turn electrical components on/off -1. Enter "9" with the number keys, then press the 2. Enter the desired number from the following table. 3. Press the 4. Press the
Number 1 2 3 5 6 8 10 11 12 13 15 17 18 19 20 21 30 ~ 37 38 40 ~ 48
key.
key to turn on the electrical component. key to turn off the electrical component.
Electrical Component Main Motor + Quenching Lamp Charge Corona + Standard Image Grid Charge Corona + Standard ID Sensor Grid Transfer Corona Separation Corona Erase Lamp ID Sensor LED Toner Supply Motor Registration Clutch Paper Feed Clutch Relay Roller Clutch Machine Shut Off Exhaust Blower Motor Optics Cooling Fan Exposure Lamp + Optics Cooling Fan Total Counter Development Bias Voltage in 40-volt steps starting at--120 volts Development Bias Voltage =--500 volts Grid Voltage in 60-volt steps starting at--400 volts
47
A202/A203 Copier
15.6 SP MODE 9--OUTPUT CHECK
SERVICE PROGRAM MODE
24 February 1997
15.7 SERVICE CALL AND USER CODE TABLE
NOTE: Only items marked with V are different from A151 and A152 copiers. Service Call Code NOTE: Due to the small capacity of EEPROM, the individual service call counters that were available in the base copiers have been eliminated.
E-code Contents Exposure Lamp Error The feed back signal becomes higher than 4.2 volts (rms) for 1.0 second when the exposure lamp is on, or it becomes higher than 1.0 volt (rms) for 1.0 second when the exposure lamp is off. Exposure Lamp Error The feed back signal falls below 0.5 volt (rms) for 1.0 second when the exposure lamp is on, or the exposure lamp stays on for longer than 10 seconds. Zero Cross Signal Error The CPU does not receive the zero cross signal within 2.0 seconds. Frequency Detection Error · The detected frequency is not within 45 ~ 65 Hz. · The fusing lamp stays on for longer than 38 seconds while the main motor is off. Scanner Home Position Error The scanner home position sensor's output remains LOW (de-actuated) for 9 seconds after the main switch is turned on. Scanner Home Position Error The scanner home position sensor's output remains HIGH (actuated) for 1.0 second after the scanner starts. Lens Home Position Error (A203 copier only) The lens home position sensor's output remains LOW (de-actuated) for 6.0 seconds after the lens moves to the home position. Lens Home Position Error (A203 copier only) The lens home position sensor's output remains HIGH (actuated) for 4.0 seconds after the lens leaves the home position. 4th/5th Mirror Home Position Error (A203 copier only) The 4th/5th mirror home position sensor's output remains LOW (de-actuated) for 3.0 seconds after the 4th/5th mirror assembly moves to the home position. Note
11
12
13
V 14
21
22
28
29
2A
48
24 February 1997
SERVICE PROGRAM MODE
2B
40
V 52
SP97 must be performed to clear this service call condition.
V 53
V 54
V 55
V 70
V 96
49
A202/A203 Copier
E-code
Contents 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). Fusing Warm-up Error The temperature detected by the thermistor does not reach 150°C within 25 seconds after the main switch is turned on. Fusing Overheat The temperature detected by the thermistor becomes higher than 230°C. Fusing Error The temperature detected by the thermistor does not rise more than 20°C within 12 seconds when the fusing lamp is turned on continuously in the main motor off condition. Fusing Thermistor Open The temperature detected by the thermistor does not reach 40°C within 15 seconds after the main switch is turned on. Used Toner Overflow The overflow counter reached 80 k copies or the toner cartridge was replaced 10 times. DF Timing Pulse Error The DF CPU does not receive a DF timing pulse within 100 milliseconds. Main Switch Error The main switch does not turn off within 8.5 seconds after the auto shut off signal is sent to the main switch. -- Possible Cause -· Defective main switch · Poor connection of main switch relay harness
Note
SERVICE TABLES
24 February 1997
16. SERVICE TABLES
16.1 TEST POINTS
Copier Main Board
Number TP101 TP102 TP103 TP105 TP106 JP101 Function HET (Fusing Thermistor) ADS (Auto Image Density Sensor) Adjust the voltage to +2.5 ± 0.1 volts with VR101. ETH (Optics Thermistor) PSE (ID Sensor Voltage) Adjust the voltage to +4.0 ± 0.2 volts with VR102. EXPO (Exposure Lamp Voltage) Key Counter (Cut this jumper wire when installing the key counter on the machine.)
16.2 DIP SWITCHES AND JUMPER SWITCHES
The following jumper switches are not included.
V JPS101-R (Upper) V JPS101-C (Lower)
16.3 VARIABLE RESISTORS
CC/Grid/Bias Power Pack
Number VRC VRG VRB Function Adjusts the charge corona current Adjusts the standard grid voltage Adjusts the standard development bias voltage
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24 February 1997
PREVENTIVE MAINTENANCE SCHEDULE
17.1 PM TABLE
The DF section has been changed. The copier section is the same.
EM 24 k DOCUMENT FEEDER (A662) (for originals) Transport Belt C R Friction Belt C R Pick-up Roller C C Feed Roller C C 48 k R R C C Notes Belt cleaner Belt cleaner Soft cloth dampened with water Soft cloth dampened with water
V Transport Belt has been made a PM part. V The cleaning method has been changed.
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A202/A203 Copier
17. PREVENTIVE MAINTENANCE SCHEDULE
REPLACEMENT AND ADJUSTMENT
24 February 1997
18. REPLACEMENT AND ADJUSTMENT
18.1 TONER SUPPLY MOTOR REPLACEMENT
[A]
[B] [C]
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. Remove the motor [B] from the bracket (2 screws). NOTE: When reinstalling, make sure that the hole [C] is positioned down, as shown.
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24 February 1997
REPLACEMENT AND ADJUSTMENT
[A]
[C]
[B]
A203R501.wmf
1. Open the front cover. 2. Remove the following parts:
· Inner cover · Development unit · Cleaning unit · Charge corona unit · Upper rear cover
3. Hold down the top of the upper unit and open the upper unit by pushing the release lever. 4. Remove the drum unit (2 screws). NOTE: Cover the drum with some sheets of paper to prevent the drum from being exposed to light. 6. Disconnect the connector [A] (CN127) from the main control board [B]. 7. Remove the quenching lamp [C] from the copier frame as shown. NOTE: Do not use alcohol to clean the quenching lamp. This damages the resin in the covers of the LEDs.
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A202/A203 Copier
18.2 QUENCHING LAMP REPLACEMENT
REPLACEMENT AND ADJUSTMENT
24 February 1997
18.3 CHARGE CORONA CURRENT ADJUSTMENT
[B]
[A]
A203R502.img
ADJUSTMENT STANDARD DC --400 ± 3 µA
Adjusting VR VRC
SP Mode 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. 2) Keep the high voltage wire terminal [A] away from the copier frame. Otherwise, electrical leakage may interfere with current measurement. 1. Turn off the main switch. 2. Disconnect the charge corona terminal [A] from the CC/Grid/Bias power pack [B]. 3. Select the dc 2 mA range on the digital multimeter. 4. Connect the multimeter leads as shown, then measure the charge corona current. NOTE: Keep the multimeter leads away from the main board. 5. Turn on the main switch, close the front cover safety switch and turn on the charge corona using SP9-2. 6. Adjust the charge corona current to --400 ± 3 µA by turning VRC on the CC/Grid/Bias power pack. 7. Press the key and turn off the main switch.
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24 February 1997
REPLACEMENT AND ADJUSTMENT
[A]
A203R503.img
ADJUSTMENT STANDARD DC --760 ± 10 µA
Adjusting VR VRG
SP Mode 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. 1. Set the multimeter range to dc 1,500 V and connect the multimeter leads as shown. NOTE: Keep the multimeter leads away from the main board. 2. Turn on the main switch, close the front cover safety switch, and turn on the grid voltage using SP9-46. 3. Adjust the grid voltage to --760 ± 10 V by turning VRG on the CC/Grid/Bias power pack [A]. 4. Press the key and turn off the main switch.
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A202/A203 Copier
18.4 GRID VOLTAGE ADJUSTMENT (SP9-46)
REPLACEMENT AND ADJUSTMENT
24 February 1997
18.5 DEVELOPMENT BIAS VOLTAGE ADJUSTMENT (SP9-38)
[A]
A203R504.img
ADJUSTMENT STANDARD DC --500 ± 10 V
Adjusting VR VRB
SP Mode 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. 1. Set the multimeter range to dc 1,500 V and connect the multimeter leads as shown. NOTE: Keep the multimeter leads away from the main board. 2. Turn on the main switch, close the front cover safety switch, then turn on the development bias using SP9-38. 3. Adjust the development bias voltage to --500 ± 10 V by turning VRB on the CC/Grid/Bias power pack [A]. 4. Press the key and turn off the main switch.
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24 February 1997
REPLACEMENT AND ADJUSTMENT
[A]
[B]
A203R505.img
[C]
A203R506.img
[D]
A203R507.img
ADJUSTMENT STANDARD DC --93.6 ± 2 µA
Adjusting VR VRT
SP Mode SP9-5
1. 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. 2. Remove the seal [C] from the transport unit. 3. Select the dc 200 µA range on the digital multimeter. 4. Turn on the main switch, close the front cover safety switch, and turn on the transfer corona using SP9-5. 5. Adjust the transfer corona current to dc --93.6 ± 2 µA using VRT on the TC/SC power pack [D]. 6. Press the key and turn off the main switch.
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A202/A203 Copier
18.6 TRANSFER CORONA CURRENT ADJUSTMENT (SP9-5)
REPLACEMENT AND ADJUSTMENT
24 February 1997
18.7 SEPARATION CORONA CURRENT ADJUSTMENT (SP9-6)
[B]
[A]
A203R508.img
[C]
A203R506-2.img
[D]
A203R509.img
ADJUSTMENT STANDARD AC 145.6 ± 5.0 µA
Adjusting VR VRD
SP Mode SP9-6
1. 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. NOTE: Make sure that the drum shoe does not touch the pick-off pawls. 2. Remove the seal [C] from the transport unit. 3 Select the ac 200 µA range on the digital multimeter. 4. Turn on the main switch, close the front cover safety switch, and turn on the separation corona using SP9-6. 5. Adjust the separation corona current to ac 145.6 ± 5.0 µA using VRD on the TC/SC power pack [D]. 6. Press the key and turn off the main switch.
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