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Ricoh Aficio FT4027, Service Manual

The Ricoh Aficio FT4027 Service Manual is a comprehensive guide that allows you to easily troubleshoot and repair your printer. This invaluable resource can be downloaded for free from manualshive.com, providing you with step-by-step instructions and diagrams to ensure optimal performance of your Ricoh printer.

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2. MECHANICAL COMPONENT LAYOUT

– A156 copier – 

NOTE: 1. The A153 copier is the same as the A156 copier except that the A153

does not have a duplex tray or an LCT.

2. The A155 copier is the same as the A156 copier except that the A155

does not have a duplex tray.

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FSM

2-3

FT5535/4527/4522

Summary of Contents for Aficio FT4027

Page 1: ...FT5535 5035 4527 4027 4522 4022 FIELD SERVICE MANUAL ...

Page 2: ... become extremely hot while the copier is operating Be careful to avoid touching those components with your bare hands HEALTH SAFETY CONDITIONS 1 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 OBSERVANCE OF ELECTRICAL SA...

Page 3: ...nce with local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance with local regulations 4 When keeping used lithium batteries from the main control boards in order to dispose of them later do not store more than 100 batteries from the main control boards per sealed box Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build up...

Page 4: ...SECTION 1 OVERALL MACHINE INFORMATION ...

Page 5: ...7 Minimum A5 81 2 x 51 2 sideways Copy Paper Weight Paper tray 52 128 g m2 14 34 lb A153 A155 and A156 copiers 64 90 g m2 17 24 lb A157 A159 and A160 copiers By pass 52 157 g m2 14 42 lb LCT 52 128 g m2 14 34 lb Duplex copying 64 105 g m2 17 24 lb Reproduction Ratios 4 Enlargement and 6 Reduction A4 A3 Version LT DLT Version Enlargement 200 141 122 115 200 155 129 121 Full size 100 100 Reduction 9...

Page 6: ...ying 0 64 KW 0 72 KW Warm up 0 95 KW 0 97 KW Stand by 0 15 KW 0 17 KW Energy Saver 1 0 14 KW 0 16 KW 2 0 12 KW 0 13 KW 3 0 09 KW 0 10 KW 4 0 07 KW 0 08 KW 5 0 05 KW 0 06 KW Auto Off 0 02 KW 0 04 KW NOTE 1 Full System Copier ADF Paper Tray Unit 10 Bin S S 2 Energy Saver See SP1 105 002 3 Auto Off See SP5 305 Noise Emission A153 and A156 copiers A157 and A160 copiers Copier Only Full System Copier O...

Page 7: ...176 4 lb Zoom From 50 to 200 in 1 steps Copying Speed copies minute A4 sideways 11 x 81 2 A3 11 x 17 B4 81 2 x 14 A153 and A156 copiers 35 20 19 22 A157 and A160 copiers 27 15 14 17 A161 and A162 copiers 22 12 Warm Up Time A153 and A156 copiers Less than 110 seconds 20 C A157 and A160 copiers Less than 80 seconds 20 C A161 and A162 copiers Less than 60 seconds 20 C First Copy Time Paper Feed Stati...

Page 8: ...105g m2 21 5 27 9 lb paper Toner Replenishment Cartridge exchange 415 g cartridge Toner Yield 17K Copies cartridge Developer Replenisment Type 1 1Kg Developer Yield A153 A156 120K A157 A160 100K A161 A162 100K Optional Equipment Platen cover Document feeder Paper tray unit with two paper trays Paper tray unit with three paper trays 10 bin micro sorter 20 bin mini sorter 10 bin sorter stapler 20 bi...

Page 9: ...SECTION 2 COMPONENT LAYOUT AND DESCRIPTION ...

Page 10: ...1 MACHINE CONFIGURATION 1 1 COPIER Rev 7 95 FSM 2 1 FT5535 4527 4522 ...

Page 11: ...1 2 OPTIONAL EQUIPMENT Only available on models FT5535 and FT4527 Not for use on FT4022 4522 A161 A163 copiers Rev 7 95 FT5535 4527 4522 2 2 FSM ...

Page 12: ...opier except that the A153 does not have a duplex tray or an LCT 2 The A155 copier is the same as the A156 copier except that the A155 does not have a duplex tray 14 5 30 31 32 33 34 35 36 37 38 1 2 3 4 28 27 26 25 24 23 22 21 20 19 18 17 16 13 12 11 10 9 8 7 6 29 15 FSM 2 3 FT5535 4527 4522 ...

Page 13: ...rs are the same as the A160 A162 copiers except that the A157and A161 do not have a duplex tray or an LCT Rev 7 95 14 5 30 31 32 33 34 35 36 37 38 1 2 3 4 28 27 26 25 24 23 22 21 20 19 18 17 16 13 12 11 10 9 8 7 6 29 15 FT5535 4527 4522 2 4 FSM ...

Page 14: ...er 20 Separation Roller 21 Large Capacity Tray 22 Vertical Transport Rollers 23 Paper Feed Roller The roller for A153 A156 copiers is different from that for A157 160 161 162 copiers 24 Friction Pad 25 Duplex Friction Roller 26 Duplex Feed Roller 27 Jogger Fence 28 Transfer Belt 29 Transfer Belt Cleaning Blade 30 Lower Paper Tray 31 End Fence 32 Entrance Rollers 33 Pick off Pawls 34 Pressure Rolle...

Page 15: ...3 PAPER PATH 3 1 NORMAL COPYING A156 copier A160 A162 copier Rev 7 95 FT5535 4527 4522 2 6 FSM ...

Page 16: ...3 2 DUPLEX COPYING A156 copier A160 A162 copier Rev 7 95 FSM 2 7 FT5535 4527 4522 ...

Page 17: ... machines only Interfaces the LCT control signal between the main board and the LCT Motors M1 88 Main Drives the main unit components M2 79 Toner Bottle Drive Rotates the toner bottle to supply toner to the toner supply unit M3 97 Upper Tray Lift A153 machines only Raises the bottom plate in the upper paper tray M4 86 Lower Tray Lift A153 A156 machines only Raises the bottom plate in the lower pap...

Page 18: ... LCT machines only Sends a signal to the CPU to stop lowering the LCT bottom plate S10 26 LCT Paper End LCT machines only Informs the CPU when the LCT runs out of paper S11 28 LCT Upper Limit LCT machines only Sends a signal to the CPU to stop lifting the LCT bottom plate S12 28 Registration Detects the leading edge of the copy paper to determine the stop timing of the paper feed clutch and detect...

Page 19: ...etects the home position of the duplex end fence jogger S33 22 Original Length Option for N American models Detects original length for 11 x 15 paper Switches SW1 33 By pass Feed Table Detects whether the by pass feed table is open or closed SW2 36 Upper Tray Non duplex machines only Detects whether the upper paper tray is in place or not SW3 35 Lower Tray Detects whether the lower paper tray is i...

Page 20: ...e duplex tray or to the paper exit SOL3 98 LCT Pick up LCT machines only Picks up paper from the LCT SOL4 80 Upper Tray Pick up A153 machines only Controls the up down movement of the pick up roller in the upper paper tray SOL5 82 Lower Tray Pick up A153 A156 machines only Controls the up down movement of the pick up roller in the lower paper tray SOL6 81 Upper Tray Separation A153 machines only C...

Page 21: ... Optics Monitors the temperature of the optics cavity TH4 49 Drum Charge Monitors the temperature of the drum charge roller Thermofuses TF1 68 Main Fusing Provides back up overheat protection in the fusing unit TF2 67 Secondary Fusing Provides back up overheat protection in the fusing unit TF3 18 Exposure Lamp Opens the exposure lamp circuit if the 1st scanner overheats Counters CO1 40 Total Keeps...

Page 22: ...Clutch Gear 4 Scanner Drive Motor 5 Scanner Drive Pulley 6 Transfer Belt Drive Gear 7 Fusing Unit Drive Gear 8 Main Motor 9 Main Pulley 10 Registration Clutch Gear 11 By pass Feed Clutch Gear 12 Development Drive Clutch Gear 13 Toner Supply Clutch Gear 1 2 3 4 5 6 9 10 11 12 13 7 8 FSM 2 13 FT5535 4527 4522 ...

Page 23: ...Gear A153 A155 only 2 Lower Paper Feed Clutch Gear 3 Relay Clutch Gear 5 3 A157 A160 A161 A162 1 Upper Paper Feed Clutch Gear A157and A161 only 2 Lower Paper Feed Clutch Gear 3 Relay Clutch Gear Rev 7 95 1 3 2 1 3 2 FT5535 4527 4522 2 14 FSM ...

Page 24: ...SECTION 3 INSTALLATION ...

Page 25: ...t will not be subjected to sudden temperature changes b where it will not be directly exposed to cool air from an air conditioner c where it will not be directly exposed to heat from a heater 7 Do not place the machine where it will be exposed to corrosive gases 8 Do not install the machine at any location over 2 000 m 6 500 feet above sea level 9 Place the copier on a strong and level base 10 Do ...

Page 26: ...n 28 5 cm 11 3 2 Copier only Receiving Tray 103 0 cm 40 6 with LCT 125 8 cm 49 6 Copier A554 Sorter Stapler 103 2 cm 40 7 with LCT 126 0 cm 49 7 Copier A555 Sorter Stapler 100 1 cm 39 5 with LCT 122 9 cm 48 4 Copier A556 Sorter 96 6 cm 38 1 with LCT 119 4 cm 47 1 See Note 2 Your machine More than 39 cm 15 4 More than 10 cm 4 0 More than 70 cm 27 6 More than 28 5 cm 11 3 See Note 1 REAR FRONT FT553...

Page 27: ...iring 1 Input voltage level 120V 60Hz More than 12 A for North America 220V 240V 50Hz More than 7 A for Europe 220V 50Hz More than 7 A for Asia 110V 60Hz More than 12 A for Taiwan 220V 60Hz More than 7 A for Saudi Arabia Philippines 2 Permissible voltage fluctuation 10 3 Do not set anything on the power cord FSM 3 3 FT5535 4527 4522 ...

Page 28: ... 2 Symbol Explanation Decal except for the A156 copier 1 3 Optional Zoom Function Decal 1 4 Optional Margin Adjustment Function Decal 1 5 Combine Originals Explanation Decal except for the A156 copier 1 6 Receiving Tray 1 7 Operating Instructions except for 27 machines 1 8 User Survey Card 17 machines only 1 9 New Equipment Condition Report 1 FT5535 4527 4522 3 4 FSM ...

Page 29: ...he scanner lock pin when transporting this copier If not skewed image may result 1 Remove the scanner lock pin A and red tag B as shown 2 A155 A156 A159 A160 copiers only Remove the strips of tape and the sheet of paper C Also remove the strip of tape on the LCT 3 Pull out the paper tray D and remove the strips of tape and the bottom plate stopper E Then install the paper tray in the copier 1 tray...

Page 30: ...and a sheet of paper D 3 Open the upper duplex guide plate E and remove the strips of tape F 4 Open the lower duplex guide plate G and remove the styrofoam support H and the sheet of paper I 5 Install the duplex tray in the copier F I G B H C B A F E D A156 copier F I G B H C B A F E D A160 copier FT5535 4527 4522 3 6 FSM ...

Page 31: ...tch actuator lock bracket C as shown 8 Turn the A1 lever D counterclockwise to lower the transfer belt unit Then remove the cushion sheet E 9 Remove the blade release wedge F together with the pick off pawl release mylar G 10 Return the A1 lever to the set position C A B B F G E D C A B A157 A159 A160 copiers FSM 3 7 FT5535 4527 4522 ...

Page 32: ...e holder assembly D and ú swing out the bottle holder assembly D 13 Remove the knob screw E and disconnect the white connector F 14 Pull down the development unit lock lever G from under the plate and pull out the development unit H Then place it on a clean sheet of paper Rev 7 95 A C B D F E G H FT5535 4527 4522 3 8 FSM ...

Page 33: ...evenly Then pour in all the remaining developer and rotate the gear again NOTE To prevent the developer from spilling do not rotate the gears in the other direction 17 Remount the toner supply unit on the development unit 2 screws and connect the white connector NOTE Make sure that the positioning rib E sits in the groove F 18 Install the development unit in the copier 1 knob screw and 1 connector...

Page 34: ...h up the bottle holder lock lever so that the knob screw holes are aligned 3 Secure the bottle holder lock lever with the knob screw CAUTION Do not swing the bottle holder assembly all the way into its original position in the machine without sliding and locking it into position exactly as described above Otherwise the assembly will be damaged 21 Install a toner bottle by following the instruction...

Page 35: ...ey twice 2 Enter 2 and press the Enter key 3 Enter 207 and press the Enter key 4 Press the Start key NOTE The machine will automatically stop when compulsory toner supply is completed It takes about 30 seconds 5 Compulsory toner supply must be performed twice in order to supply enough toner to the toner hopper so press the Start key again A156 copier only Select the proper language for the guidanc...

Page 36: ...per into the paper trays and the copy tray 32 Attach the appropriate paper size decals A to the paper trays Also A156 A160 copiers only attach the duplex decal to the duplex tray NOTE Paper size decals are used also for the paper tray unit Save the remaining decals for use with the paper tray unit 33 Install the optional platen cover B as follows if necessary 1 Install 2 stud screws C on the top c...

Page 37: ...Feed A153 and A157 copiers 5th tray By pass Feed Copier Paper Tray Unit 2nd tray 3rd tray 4th tray 5th tray LCT 1st tray A155 and A159 copiers Copier Paper Tray Unit LCT By pass Feed 1st tray 2nd tray 3rd tray 4th tray A156 and A160 copiers The diagrams on this page show how the paper feed stations are numbered in the various models FSM 3 13 FT5535 4527 4522 ...

Page 38: ...ted with the paper size slider A4 A3 Version LT DLT Version A3 lengthwise 11 x 17 B4 lengthwise 81 2 X 14 A4 lengthwise 81 2 x 11 A4 sideways 11 x 81 2 B5 lengthwise A4 lengthwise B5 sideways A4 sideways A5 sideways 81 2 x 51 2 81 2 x 11 11 x 15 11 x 81 2 10 x 14 11 x 17 F4 81 2 x 13 lengthwise F4 81 2 x 13 lengthwise 8 x 10 NOTE For the 1st tray a wider range of paper sizes can be selected with S...

Page 39: ...A155 A159 copiers A156 A160 copiers Paper Tray Indicator Paper Size Selection Paper Tray Indicator Paper Size Selection Paper Tray Indicator Paper Size Selection SP5 019 001 SP5 019 002 2 2nd Tray SP5 019 003 3 3rd Tray 3 3rd Tray 3 3rd Tray SP5 019 004 4 4th Tray 4 4th Tray 4 4th Tray SP5 019 005 5 5th Tray 5 5th Tray By pass Feed SP5 019 006 By pass Feed By pass Feed T LCT SP5 019 007 1 SPECIAL ...

Page 40: ... Size Selection for the 1st Tray For the 1st tray a wider range of paper sizes can be selected using SP5 019 007 for A153 A156 A157 and A160 copiers or SP5 019 008 for A155 and A159 copiers NOTE The definition of the 1st tray differs with the type of copier See section 2 3 1 Paper Feed Station Definition If a special paper size is selected the machine ignores the paper size set with the paper size...

Page 41: ...PIERS ONLY 2 4 1 Accessory Check Check the quantity and condition of the accessories in the box against the following list Description Qty 1 Installation Procedure 1 2 Sorter Adapter Front Cover 1 3 Clip 3 4 Philips Pan Head Screw M4 x 6 4 FSM 3 17 FT5535 4527 4522 ...

Page 42: ... sorter adapter C 4 tapping screws in the paper exit section of the copier 4 Attach the sorter adapter front cover D to the copier front cover 3 clips E as shown NOTE Be sure to push the clips in completely 5 Check that the rotation of the exit rollers F is synchronized with the rotation of the fusing unit knob G A B C D F E G FT5535 4527 4522 3 18 FSM ...

Page 43: ...wer cord before starting the following procedure If the 20 bin sorter stapler A554 has been already installed do step 1 1 Remove the 20 bin sorter stapler and the sorter stapler mounting frame from the copier See 20 BIN SORTER STAPLER INSTALLATION PROCEDURE 2 A153 A155 A157 and A159 copiers Remove the 1st and 2nd paper trays 3 A156 and A160 copiers Remove the duplex unit and the 1st paper tray Rev...

Page 44: ...ws 9 Pass the two projections G through the opening H in the copier main frame then mount the heater cover I on the bottom of the copier main frame 1 screw CAUTION The heater cover is necessary because the surface of the heater becomes very hot 10 Insert the clamp J into the rear frame and join the connectors K 11 Clamp the harness L to the two clamps J and M as shown to prevent the harness from t...

Page 45: ...as a service part See the parts catalog CAUTION Unplug the copier power cord before starting the following procedure 1 Remove the exposure glass See Replacement and Adjustment Exposure Glass Removal 2 Remove the rear cover See Replacement and Adjustment Outer Cover Removal 3 Insert the two clamps A as shown 4 Mount the anti condensation heater B 2 screws 5 Pass the connector C through the opening ...

Page 46: ...e belt and mirrors do not touch the heater harness while they are functioning Also make sure that the heater harness does not interfere with the light path to the ADS sensor board NOTE Tell the customer that even when the copier main switch is turned off the copier power cord should be plugged in Otherwise the optics anti condensation heater will not function FT5535 4527 4522 3 22 FSM ...

Page 47: ...t and Adjustment Exposure Glass Removal 2 Remove the lens housing cover See Replacement and Adjustment Scanner Drive Belt Replacement 3 Pull out the light yellow connector A from under the optical rail 4 Connect the light yellow connector A to the connector B of the optional sensor C 5 Mount the optional sensor C as shown 1 tapping screw 6 Remount the lens housing cover D 2 tapping screws and remo...

Page 48: ...e rear cover See Replacement and Adjustment Outer Cover Removal 3 A153 A155 and A156 copiers only Remove the optics cooling fan duct A 2 tapping screws 4 Remove the former ADS sensor board B 2 tapping screws and 1 connector 5 Mount the optional ADS sensor board C 2 tapping screws and connect the connectors D of the ADS sensor board to the adapter harness E 6 Clamp the harness E to the clamp F as s...

Page 49: ...he cap B with nippers 3 Pass the four pin connector C of the key counter holder D through the opening E and couple it with the key counter connector F 4 Mount the key counter holder D 2 screws 5 Reinstall all the covers and check the key counter s operation 6 Make sure that SP mode 5 401 is set to 0 then switch the power off and cut JP2 on the main board Rev 7 95 F D A C B E FSM 3 25 FT5535 4527 4...

Page 50: ... INSTRUCTIONS 10 AND 22 COPIERS ONLY 1 Peel off the backing film A 2 Attach the brand decal B to the indent in the front cover C as shown A A C B C B A153 A155 and A156 Copiers A157 A159 and A160 Copiers FT5535 4527 4522 3 26 FSM ...

Page 51: ...SECTION 4 SERVICE TABLES ...

Page 52: ...m surface 4 Store the drum in a cool dry place away from heat 5 Take care not to scratch the drum as the photoconductive layer is thin and is easily damaged 6 Never expose the drum to corrosive gases such as ammonia gas 7 Always keep the drum in its protective sheet when it is out of the copier Doing so avoids exposing the drum to bright light or direct sunlight This will protect the drum from lig...

Page 53: ...ains or setting power may cause white spots or white bands on copies due to insufficient drum charge 3 Prevent the drum charge roller from being exposed to dusty air Dust on the drum charge roller may cause white spots on copies due to insufficient drum charge 4 Never use alcohol or water to clean the drum charge roller Alcohol or water corrode the surface of the drum charge roller Wipe with a dry...

Page 54: ...DS and VL patterns under the left scale bracket 5 To clean the mirrors and lens use only a clean soft cloth dampened with alcohol or water 6 The mirror surface with the reflective coating must face the light path The spring plates must contact the reverse side of the mirror the side without the reflective coating 7 If you ever adjust the exposure lamp voltage with SP4 001 be sure to perform auto A...

Page 55: ...it 7 The doctor gap and the development roller position must not be adjusted in the field as they are precisely adjusted at the factory using special tools Do not loosen any screws except for those needed when removing the toner supply unit 8 Before pulling out the development unit disconnect the connector and release the development unit lock lever 9 When putting the development unit back in the ...

Page 56: ...g the original directly on the exposure glass be sure to lower the platen cover or document feeder before pressing the Start key For the first copy using by pass feed the copier scans full size If the platen cover is opened a completely black image is developed on the drum outside the copy paper size This black image is transferred not to the copy paper but to the transfer belt The toner transferr...

Page 57: ...the paper must be copy side down 2 For the by pass feed table and the LCT the paper must be copy side up 8 Do not leave paper or originals on top of the LCT Any paper left there may be fed into the copier and damaged 1 11 FUSING UNIT 1 Be careful not to damage the edges of the hot roller strippers or their tension springs 2 Do not touch the fusing lamps with bare hands 3 Make sure that the fusing ...

Page 58: ...in sequence NOTE 1 The above procedure must be finished within 20 seconds 2 Hold the final key for more than 3 seconds 3 When SP mode is selected 1 blinks in the 3rd digit of the copy counter the Auto Image Density indicator starts blinking and the reduce enlarge indicator turns off How to leave the SP mode Press the key three times or turn off the main switch NOTE The above procedure must be fini...

Page 59: ...are no third level programs in this SP mode Do not press the or keys at this time Note If you need to return to one level before press the key 3 Input the required setting as explained in the following section 2 1 2 Changing the Value of an SP Mode 1 Enter the SP mode 2 Select the required program mode as explained above 3 The current setting will be displayed in the reduce enlarge indicator 4 Ent...

Page 60: ... Counter SP7 803 SP7 807 001 Total Service Call Counters SP7 401 SP7 402 SP7 807 002 Total Copy Paper Misfeed Counters SP7 502 SP7 504 SP7 807 003 Total Original Misfeed Counters SP7 503 SP7 505 SP7 810 Copy Counters SP7 002 SP7 101 SP7 301 SP7 811 DF Original Counter SP7 205 SP7 816 001 Total sheets of paper fed from the Upper Tray Except for A156 and A160 copiers SP7 204 001 SP7 816 002 Total sh...

Page 61: ...aper fed from the Paper Trays SP7 204 DF Original Counter SP7 205 Stapler Counter SP7 206 Reduction Enlargement Full Size Copy Counters SP7 301 Total Service Call Counter SP7 401 Individual Service Call Counters SP7 402 Total Jam Counter SP7 501 Total Copy Jam Counter SP7 502 Total Original Jam Counter SP7 503 Copy Jam Counters for Each Location SP7 504 Original Jam Counters for Each Location SP7 ...

Page 62: ...ll a new OPC drum 2 Clean the optics sensors and inside the copier if necessary 3 Do SP 3 123 as follows 3 1 Enter SP3 123 Do not press the key after entering this SP mode until you are sure you want to initialize the drum data 3 2 Press the key The drum data will be initialized 4 Perform the following SP modes in the following order see Practical SP Mode Use Tables for details 1 SP3 001 ID Sensor...

Page 63: ...e only when the key and the key are pressed at the same time 3 Turn the main switch off and on Recovering the machine after a memory reset CAUTION If SP5 801 is performed the drum rotation timer for process control and the TD sensor initial setting data are reset As a result the old drum and the old developer cannot be used any more Otherwise dirty background and or toner scattering will appear on...

Page 64: ... Horizontal H P Adjustment SP4 101 Horizontal Magnification Adjustment SP4 102 Lens Error Correction SP4 103 Focus Adjustment 5 Perform the following SP modes in the following order see Practical SP Mode Use Tables for details 1 SP2 214 TD Sensor Initial Setting 2 SP3 123 Drum Initialization 3 SP3 001 ID Sensor Initial Setting 4 SP3 112 Forced VR Detection 5 SP4 001 Exposure Lamp Voltage Adjustmen...

Page 65: ...stic System not available in these models CSS means Customer Support System only available in Japan 8 Type 1 A153 A155 and A156 copiers Type 2 A157 A159 and A160 copiers 2 3 1 Quick Reference The following is a quick reference list of the SP Modes Mode No Function Paper Feed Paper Transport Fusing 1 001 Registration 1 003 xxx Paper Feed Timing 1 008 Misfeed Detection 1 103 Fusing Idling 1 104 Fusi...

Page 66: ...Charge Roller Temperature 2 812 Drum Reverse Rotation Adjustment 2 901 Drum Charge Roller Cleaning Interval 2 902 Not Used Process Control 3 001 ID Sensor Initial Setting 3 002 ID Sensor Initial Setting Display 3 103 xxx ID Sensor Output Display 3 105 Forced VL Detection 3 106 Initial VLP VLG Display 3 107 Current VLP VLG Display 3 111 Current VRP VRG Display 3 112 Forced VR Detection 3 123 Drum I...

Page 67: ... Double Count 5 106 Image Density Level Correction ADS Correction 5 107 xxx Image Shift Margin Adjustment 5 108 Edge Erase Margin Adjustment 5 110 Center Erase Margin Adjustment 5 113 Coin Lock Installation 5 115 Duplex Image Shift Back Side Margin 5 121 T C Total Counter Count Up Timing 5 305 Auto Off Time Setting 5 401 User Code Mode 5 402 User Code Counter Check 5 404 xxx User Code Counter Clea...

Page 68: ...Copy for Last Odd Originals in Duplex 6 006 xxx DF Registration Adjustment 6 009 DF Free Run with Paper 6 010 Auto APS Select DF 6 011 Thick Thin Original Mode Selection 6 101 Sorter Installation 6 102 Sorter Stack Limit 6 104 Staple Sheet Limit 6 107 Sorter Free Run Mode Counters 7 001 Total Operation Time Display 7 002 Total Original Counter Display 7 003 Copy Charge Counter for RDS CSS Display ...

Page 69: ...unter The counter is not divided up by Paper Size 7 503 Total Original Jam Counter 7 504 xxx Total Jams by Location 7 505 xxx Total Original Jams by Location 7 801 xxx Main ROM Version Display 7 803 PM Counter Check 7 804 PM Counter Clear 7 807 001 SC Counter Clear 7 807 002 Copy Jam Counter Reset 7 807 003 Original Jam Counter Reset 7 808 Counter All Clear 7 810 Copy Counter Clear 7 811 DF Counte...

Page 70: ... done or not Fusing idling lasts 2 minutes 0 OFF 1 ON After selecting ON or OFF turn the main switch off and on 1 104 Fusing Temperature Control Selects the fusing lamp temperature control mode 0 On Off Control 1 Phase Control After selecting the control mode turn the main switch off and on 1 105 001 Fusing Temperature Adjustment Main Fusing Lamp Adjusts the temperature of the main fusing lamp whi...

Page 71: ...by the thermistor The temperature in energy saving mode cannot be displayed as entering SP mode takes the machine out of this mode 1 108 Forced Start Selects whether forced start is on or off 0 OFF 1 ON If forced start is switched on the copier enters the ready condition even if the fusing temperature has not reached the required value yet Use this for tests if the room temperature is low and you ...

Page 72: ... voltage 10 V per step Range Base voltage 160 V to Base voltage 160 V 2 101 001 to 2 101 002 Leading Trailing Edge Erase Margin Adjustment Adjusts the leading and trailing edge erase margins SP2 101 001 Leading edge erase margin SP2 101 002 Trailing edge erase margin 0 32 Default 16 only 2 101 001 is on the data sheet 0 5 mm per step range 0 0 mm to 16 0 mm 2 201 001 Development Bias Adjustment fo...

Page 73: ...upply Mode Selection Selects the toner supply mode In many cases the machine will change the toner supply mode automatically if either the TD or ID sensor become unreliable However sometimes it does not If the TD sensor fails you can select fixed supply mode as a temporary measure If the ID sensor fails you can select TD sensor supply mode After repairing the machine check whether the toner supply...

Page 74: ...tput 2 220 TD Sensor Initial Output Display Displays the TD sensor initial setting output after doing SP2 214 Normally 2 5 0 1 V is displayed Range 0 V to 5 0 V If it is not the sensor may be defective 2 222 Toner Supply Ratio Detect Supply Mode Selects the toner supply ratio for detect supply mode For example if the user normally makes copies of originals that are about 7 black select the 7 setti...

Page 75: ...tting Performs the ID sensor initial setting ID sensor output for the bare area of the drum VSG is adjusted to 4 0 0 2 V To start this SP mode press the Start key 3 002 ID Sensor Initial Setting Display Displays the initial setting value of the ID sensor Normally 4 0 0 2 V is displayed If the ID sensor cannot be adjusted to 4 0 0 2 V the ID sensor or the OPC drum should be cleaned 3 103 001 to 3 1...

Page 76: ...y problem is caused by process control or by the machine itself 3 901 Free Run Exposure Lamp Off Performs a free run with the exposure lamp off Start the free run by pressing the Start key and stop it by pressing the Clear Stop key Be sure to perform this mode without a development unit or too much toner will be consumed from the developer causing low image density 3 902 Forced Process Control Per...

Page 77: ... is mainly used for making factory adjustments If it is shifted by a certain amount all other SP4 011 adjustments move by the same amount See Replacement and Adjustment Copy Quality Adjustments and Side to side Registration in the ARDF manual for details on how to adjust 4 013 Scanner Free Run Starts the scanner free run Start the scanner free run by pressing the Start key and stop it by pressing ...

Page 78: ...ay Displays the current ADS sensor output 4 301 APS Sensor Function Check Check the APS sensors If they are working correctly the following value is displayed in the reduce enlarge indicator LT version 0 or 95 without optional APS 0 or 127 with optional APS A4 version 0 or 95 4 302 Optional APS Sensor LT version only Set this to 1 when installing the optional APS sensor 0 Not installed 1 Installed...

Page 79: ...n the main switch is turned on auto reset or mode cleared 1 APS 0 Manual Also see SP6 010 5 004 ADS Priority Selection Specifies whether the copier defaults to ADS or manual ID mode when the main switch is turned on auto reset or mode cleared 1 ADS 0 Manual 5 013 Counter Up Down Selection Selects whether the counter counts up or down 1 Up 2 Down 5 017 Maximum Copy Quantity Copy Limit Limits the ma...

Page 80: ...ction ADS Correction Selects the image density level correction 0 Dark 1 Normal 2 Light The development bias voltage correction in ADS mode depends on this setting see ADS Correction in the Process Control section for details 5 107 001 to 5 107 002 Image Shift Margin Adjustment This controls the margin width adjustment for the Left and Right margin adjustment keys SP5 107 001 Left SP5 107 002 Righ...

Page 81: ... one sided originals If the image shift mode has been selected with SP5 908 and if the user uses image shift mode this SP mode has no effect 5 121 T C Total Counter Count Up Timing Determines whether the total counter counts up at paper feed or at paper exit 0 Feed 1 Exit 5 305 Auto Off Time Setting Sets the time to go into the auto off condition 1 120 minutes 1minute per step Default 60 minutes 5...

Page 82: ...P5 404 001 Deletes individual user code numbers Enter the required user code at the numeric keys then press the key To see which user codes are being used use SP5 405 SP5 407 002 Deletes all the user code numbers 5 408 Number of Registered User Codes Display Displays the number of registered user codes in the reduce enlarge indicator 5 501 001 PM Interval Setting Sets the PM interval 1000 copies p...

Page 83: ... switches For details see Service Tables section 2 5 5 804 Output Check Mode Turns on the electrical components individually for test purposes For details see Service Tables section 2 6 5 810 SC Reset Resets any service call condition that was caused by a level A error see the Troubleshooting section After doing SP5 810 turn the copier main switch off and on 5 811 Machine Serial No Input For use w...

Page 84: ...o copies in cover mode Copy paper for the cover pages should be placed on the by pass feed table 1 Front Back 2 Front 5 908 Image Shift Erase Selection Selects whether to have an image shift mode or an image erase mode 1 Erase mode 2 Shift mode 5 909 10 key Zoom Size Magnification Selects whether to have a 10 key zoom function or a size magnification function 1 Size magnification 2 10 key zoom fun...

Page 85: ...ays in the duplex unit regardless of this setting 6 006 001 to 6 006 002 DF Registration Adjustment Adjusts the registration of the document feeder SP6 006 001 One sided original SP6 006 002 Two sided original 0 32 Default 16 0 3 mm per step Range 4 8 mm to 4 8 mm See Vertical Registration in the ARDF manual for details on how to use these adjustments 6 009 DF Free Run with Paper To start the DF f...

Page 86: ... 20 B4 LG A3 DLT A556 Sorter Sort Mode 30 A4 LT 15 B4 LG 10 A3 DLT Stack Mode 30 A4 LT 10 B4 LG A3 DLT A557 Sorter Sort or Stack Mode 20 A4 LT 15 B4 LG 10 A3 DLT 6 104 Staple Sheet Limit Select whether there is a stapling limit for the sorter stapler 0 OFF 1 ON OFF Copies of up to 25 pages can be stapled for all paper sizes ON The staple indicator will go out after the following limit number of pa...

Page 87: ...ay This is for use with features that are available only in Japan However it does show the total number of copies that have been made The 4th 6th digits are displayed in the reduce enlarge indicator Hold down the 0 key to display the 7th digit and hold down the key to display the 3rd 1st digits 7 101 001 to 7 101 005 Total Copies by Paper Size Displays the total number of copies by paper size The ...

Page 88: ...s made in full size mode 7 301 002 Copies made with reduction 7 301 003 Copies made with enlargement The first three digits are displayed in the reduce enlarge indicator Hold down the key to display the last three digits 7 401 Total Service Call Counter Displays the total number of service calls that have occurred 7 402 SC Counter by Service Call Displays the service call counters for each service...

Page 89: ...nal jam counter max 4 digits The first digit is displayed in the reduce enlarge indicator Hold down the key to display the last three digits 7 504 001 to 7 504 006 Total Jams by Location Displays the total copy paper jam counts by location max 4 digits The first one digit is displayed in the reduce enlarge indicator Hold down the key to display the last three digits 7 505 001 to 7 505 002 Total Or...

Page 90: ... ROM version as follows Note 09 15 21 do not exist because suffixes I O and U are not used 7 803 PM Counter Check Displays the PM counter after the last PM max 6 digits The first three digits are displayed in the reduce enlarge indicator hold down the key to display the last three digits 7 804 PM Counter Clear Resets the PM counter The counter will be reset when you press the final key when enteri...

Page 91: ... 505 To reset the counters press the key 7 808 Counter All Clear Resets the following counters After pressing the final key when entering this SP mode the counters will be reset Counters that are reset Counter check Operation Time SP7 001 Scanning Counter SP7 002 Copy Counter SP7 101 Total Sheets of Paper Fed from the Paper Tray SP7 204 DF Originals Counter SP7 205 Stapler Counter SP7 206 Reductio...

Page 92: ...ear Resets the DF counter SP7 205 After pressing the final key when entering this SP mode the counter will be reset 7 816 001 to 7 816 008 Feed Unit Counter Clear Reset one of the following counters by pressing the key SP Number Without Duplex With Duplex SP7 816 001 1st tray SP7 816 002 2nd tray 1st tray SP7 816 003 3rd tray 2nd tray SP7 816 004 4th tray 3rd tray SP7 816 005 5th tray 4th tray SP7...

Page 93: ...Image Density Level Correction 13 5 907 Cover Mode Selection 14 5 908 Image Shift Erase Selection 15 5 909 10 Key Zoom Size Magnification 16 5 107 Image Shift Margin Adjustment 17 5 108 Edge Erase Margin Adjustment 18 5 110 Center Erase Margin Adjustment 19 5 906 Manual Staple Reset Time Setting 20 6 001 SADF Auto Reset Time Setting 21 6 002 ADF Free Size Setting 22 6 011 Thick Thin Original Mode ...

Page 94: ...nit Paper not detected Paper detected 5 5th Tray Paper Feed Sensor Paper Tray Unit Paper not detected Paper detected 6 Registration Sensor Paper not detected Paper detected 7 Fusing Exit Sensor Paper not detected Paper detected 8 By pass Feed Paper Width Sensor See the Note after the end of this table 9 By pass Feed Paper End Sensor Paper detected Paper not detected 10 By pass Feed Table Switch Ta...

Page 95: ...On 45 Platen Cover Close Sensor Platen cover open Platen cover closed 46 Platen Cover Open Sensor Platen cover closed Platen cover open 47 Vertical Guide Set Switch Vertical guide closed Vertical guide open 48 Paper Exit Cover Switch Paper exit cover closed Paper exit cover open 49 Front Cover Switch Front cover closed Front cover open 50 Sorter Entrance Sensor Off On 51 Sorter Bin H P Sensor Off ...

Page 96: ...r 3 Off On 91 ADF Original Width Sensor 2 Off On 92 ADF Original Width Sensor 1 Off On 93 ADF Registration Sensor Paper not detected Paper detected 94 ADF Feed Out Sensor Paper not detected Paper detected 95 ADF Position Sensor ADF closed ADF open 96 ADF APS Start Sensor On Off 97 ADF Feed In Cover Open Sensor Cover closed Cover open 98 ADF Feed Out Cover Open Sensor Cover closed Cover open NOTE W...

Page 97: ...age do not keep the electrical component on for a long time 3rd level No Electrical Component 1 Main motor 2 Relay clutch 3 Registration clutch 4 Transfer belt contact clutch 5 Junction gate SOL 6 Not used 7 Sorter drive motor A556 and A557 sorters only 8 By pass feed CL 9 By pass feed pick up SOL 10 Upper paper feed CL 11 Upper tray separation SOL 12 Upper tray pick up SOL 13 Upper tray lift moto...

Page 98: ...r stapler motor 35 Exhaust fan Left 36 Exhaust fan Right 1 37 Optics cooling fan 1 or 2 40 Exposure lamp 41 Quenching lamp PTL 42 Toner supply CL 43 Development CL 44 Toner supply bottle motor 50 ADF feed in motor 51 ADF feed in motor reverse 52 ADF belt drive motor 53 ADF belt drive motor reverse 54 ADF feed out motor 55 ADF inverter SOL Entrance SOL 56 ADF display on Rev 7 95 FSM 4 47 FT5535 452...

Page 99: ...an be selected with the and keys A153 A157 copiers A155 A159 copiers A156 A160 copiers Paper Tray Indicator Paper Size Selection Paper Tray Indicator Paper Size Selection Paper Tray Indicator Paper Size Selection SP5 019 001 SP5 019 002 2 2nd Tray SP5 019 003 3 3rd Tray 3 3rd Tray 3 3rd Tray SP5 019 004 4 4th Tray 4 4th Tray 4 4th Tray SP5 019 005 5 5th Tray 5 5th Tray By pass Feed SP5 019 006 By ...

Page 100: ... 390 mm lengthwise A4 sideways 14 16K 267 mm x 195 mm sideways A4 lengthwise 15 16K 195 mm x 267 mm lengthwise Paper size SP settings for by pass feed See Detailed Descriptions section 11 9 3 SP Settings A4 Version LT Version 0 Paper size detected in accordance with the side fence position Paper size detected in accordance with the side fence position 1 A4 lengthwise 81 2 x 11 2 A4 sideways B5 len...

Page 101: ...P5 019 007 A153 A156 A157 and A160 copiers SP5 019 008 A155 and A159 copiers A4 LT Version 0 Paper size detected by the paper size slider 1 A3 lengthwise 2 297 mm x 432 mm maximum size 3 B4 lengthwise 4 A4 sideways 5 A4 lengthwise 6 B5 sideways 7 B5 lengthwise 8 A5 sideways 9 B6 sideways 10 200 mm x 148 mm 11 210 mm x 170 mm 12 210 mm x 340 mm 13 11 x 17 14 81 2 x 14 15 11 x 81 2 16 81 2 x 11 17 8...

Page 102: ... O 6 4 201 4 202 Auto ADS Gain Adjustment O O O 7 3 105 3 106 Forced VL Detection O O SP Number to display the adjusted value 3 2 MAJOR ADJUSTMENTS The following table shows SP modes for major adjustments in the field TONER DENSITY Detect Supply Mode Mode No Description Settings SP2 222 Toner Supply Ratio 1 7 2 15 3 30 4 60 IMAGE DENSITY Mode No Description Settings SP5 106 ADS Data Correction 0 D...

Page 103: ...per Size 2 215 TD Sensor Output 7 203 Drum Counter 2 220 TD Sensor Initial Output 7 204 Feed Unit Counter 2 802 Drum Charge Roller Temperature 7 205 DF Counter 3 002 ID Sensor Initial Setting 7 206 Staple Counter 3 103 ID Sensor Output 7 301 Total Copies by Magnification 3 106 Initial VLP VLG 7 401 SC Total Counter 3 107 Current VLP VLG 7 402 SC Counter by Each Service Call 3 111 Current VRP VRG 7...

Page 104: ...rrent feed back voltage TP12 LAMP Exposure lamp voltage feed back voltage TP13 T SENSOR Toner density sensor output TP14 ADS Auto image density sensor output TP15 RXA RXA TP16 CHA FB Drum charge roller feed back voltage TP17 DEV BIAS Development bias feed back voltage TP18 Drum charge thermistor output TP19 Not used TP20 Secondary fusing thermistor output TP21 Main fusing thermistor output FSM 4 5...

Page 105: ...Clean with the special cloth if necessary the cloth must be dry Drum Charge Roller Cleaner R R R Replace with the drum charge roller as a set Drum Charge Roller Terminal R R R Replace with the drum charge roller as a set ID Sensor C C C Blower brush After cleaning do SP3 001 then SP3 112 Roller Terminal R R R Replace with the drum charge roller as a set Erase Lamp C C C Dry cloth Quenching Lamp C ...

Page 106: ...ement Transfer Belt Cleaning Blade C R R R Used Toner Tank C C C Blower brush or vacuum cleaner FUSING UNIT Fusing Entrance and Exit Guide Plates C C C Suitable solvent Fusing Lamps I I I Replace if necessary Hot Roller R R R Pressure Roller C R C Suitable solvent Fusing Thermistors C I I I Suitable solvent Hot and Pressure Roller Bearings I I I Replace if necessary Fusing Antistatic Brush I I I R...

Page 107: ...et Roller Terminal R R R Replace with the drum charge roller as a set ID Sensor C C C Blower brush After cleaning do SP3 001 then SP3 112 Erase Lamp C C C Dry cloth Quenching Lamp C C C Dry cloth Pick off Pawls C R C Dry cloth Pre Transfer Lamp C C C Dry cloth and blower brush DEVELOPMENT UNIT Developer R R R Do SP2 214 after replacement Side Seal I I I Development Filter R R R Entrance Seal C C C...

Page 108: ...C R C Suitable solvent Fusing Thermistors C I I I Suitable solvent Hot and Pressure Roller Bearings I I I Replace if necessary Fusing Antistatic Brush I I I Replace if necessary Cleaning Roller R R R Suitable solvent Cleaning Roller Bushings I I I Replace if necessary Fusing Exit Rollers C Turn Guide Transport Rollers C Hot Roller Strippers C R R R DUPLEX TRAY Clutch Spring L L L Mobil Temp 78 See...

Page 109: ...eed Roller C R R R Water EM PM NOTE 20 BIN SORTER STAPLER A554 Transport and Exit Rollers C C Alcohol or water Bins C C Alcohol or water Bin and Paper Sensors C C Blower brush Bushings L L Launa oil if bushings generate noise Worm Gears L L Grease G501 if worm gears generate noise Bin Cam Tracks L L Grease G501 if bin cam tracks generate noise 10 BIN SORTER STAPLER A555 Transport Roller C C Alcoho...

Page 110: ...lex Tray Clutch Spring Do the following every 120K A153 A155 A156 copiers or 100K A157 A159 A160 copiers Clean the clutch assembly A Then lubricate the clutch spring with Mobil Temp 78 A FSM 4 59 FT5535 4527 4522 ...

Page 111: ...an the toner shield glass and the dust filter 1 Remove the drum and clean the ID sensor with a blower brush 2 Clean the pick off pawls 3 Clean the quenching erase and pre transfer lamps with a dry cloth Discharge any static electricity before putting them back 4 Put back the drum 5 Replace the drum charge roller drum charge roller cleaner and drum charge roller terminal and roller terminal Rev 7 9...

Page 112: ...on and relay rollers for each paper feed station by pass feed and the LCT 3 Replace the bottom plate pad for each paper feed station by pass feed and the LCT 4 Clean the registration rollers 4 Cleaning Unit every 100 or 120 k 5 Development Unit every 100 or 120 k Replace the pick up feed and separation rollers for each paper feed station by pass feed and the LCT every 200 240k 6 Paper Feed every 1...

Page 113: ...ler exit roller and turn gate transport rollers 4 Replace the hot roller strippers 5 Replace the hot roller 1 Inspect the mylars 2 Replace the feed roller and the bottom plate pad 3 Lubricate the clutch spring with Mobil Temp 78 1 Inspect the timing belts Rev 7 95 7 Transfer Belt Unit every 100 or 120 k Replace the pressure roller every 200 240k 8 Fusing Unit every 100 or 120 k Replace the cleanin...

Page 114: ...2 Forced VR Detection 4 SP4 001 Exposure Lamp Voltage Adj 5 SP4 201 Auto ADS Gain Adj 6 SP3 105 Forced VL Detection Perform these SP modes only if the exposure lamp has been replaced Make a copy of an OS A3 test chart at manual image density level 4 11 Exterior every 100 or 120 k 12 Copy Process SP Mode Settings 13 Make a Copy FSM 4 63 FT5535 4527 4522 ...

Page 115: ...ustment Tool 1 set A153 9004 WIPING CLOTH Drum Charge Roller Cloth 1 5420 9516 Test Chart OS A3 10 pcs set 1 5420 9507 Digital Multimeter 1 A008 9502 Silicone Grease G40M 1 5442 9103 Launa Oil 1 5447 9078 Heat Resistant Grease MT 78 1 5203 9501 Grease 501 1 FT5535 4527 4522 4 64 FSM ...

Page 116: ...SECTION 5 REPLACEMENT AND ADJUSTMENT ...

Page 117: ...ding screws for the upper holes 2 Remove the rear cover B 2 screws 1 1 3 Left Cover A153 A155 A156 1 Open the front cover and pull out the paper trays C 2 Remove the left cover D 2 screws A157 A159 A160 1 Open the front cover and pull out the paper trays 2 Remove the cover plate E 2 screws 3 Remove the left cover F 4 screws E F B C A D FSM 5 1 FT5535 4527 4522 ...

Page 118: ...d the LCT rear cover 2 screws 3 Remove the rear right cover D 1 screw 1 1 6 Top Cover 1 Remove the optional platen cover or the optional DF 2 Remove the top cover E 6 screws 1 1 7 Operation Panel 1 Lift up the optional platen cover or the optional DF 2 Open the front cover and slide out the toner bottle holder assembly F 1 screw and 1 knob screw 3 Remove the operation panel G 4 screws and 2 connec...

Page 119: ...e tray units C 2 Remove the two knobs D and E 1 screw each NOTE 1 Knob D is not installed in A157 A159 A160 copiers 2 When removing the knob E insert an allen key F into the hole in the registration roller shaft as shown in the illustration 3 Remove the lower right inner cover G 1 screw 1 2 3 Lower Left Inner Cover 1 Remove the front cover and open the tray units 2 Remove the lower left inner cove...

Page 120: ...at the paint mark D is positioned at the front right corner as shown This ensures that the correct side of the glass is face up this side is smoother and it generates less static electricity when the DF is used 2 2 EXPOSURE LAMP REPLACEMENT NOTE Do not touch the reflector or the new exposure lamp with your bare hands Use a strip of paper as shown Oil marks from fingers on the lamp or reflectors wi...

Page 121: ...nts and perform the following SP modes in the following order SP4 001 SP4 201 SP3 105 2 2 1 Main Fusing Lamp Interchangeability The main fusing lamp for the FT4022 4522 A161 A162 is different from that of the FT4027 4527 A157 A160 The total span of all the filaments has been expanded for the FT4022 4522 A161 A162 copier to compensate for the difference in the copies per minute and the warm up time...

Page 122: ... remove the C B high voltage supply board assembly I 2 screws 3 connectors and 1 clamp 4 Loosen the screws securing the belt tension brackets J and remove all four belt tension springs as shown A E B F C D G I H J J Platen cover A or DF Left scale B 2 shoulder screws Exposure glass C Operation panel D Top cover E Rear scale F Rear cover G Upper inner cover FT5535 4527 4522 5 6 FSM ...

Page 123: ...ening the 2 screws as shown 7 Remove the left scale bracket C with the optics thermistor 2 screws and 1 connector 8 Remove the scanner home position sensor bracket D 1 screw and 1 connector 9 Remove the lens housing cover E 2 screws 10 Remove both scanner guide rails F 1 spring plate each A B D C E F FSM 5 7 FT5535 4527 4522 ...

Page 124: ...move all four scanner drive belts NOTE When reinstalling make sure of the following points If the pulleys F have been removed make sure that they face the same direction as shown when you put them back The belt tension bracket should be tightened after all the belt tension springs have been installed Adjust the position of the 1st and 2nd scanner by using the positioning bracket kit See Scanner Po...

Page 125: ...e as a service part P N A1539001 See the parts catalog 4 Manually set the 1st C and 2nd D scanner on the pins of the scanner positioning bracket as shown 5 Tighten the belt clamps NOTE To remove the scanner positioning brackets gently lift up both scanner units and move them towards the home position 6 Reassemble the machine and check the copy quality B D C A Platen cover or DF Left scale Exposure...

Page 126: ... belt by loosening the 2 screws as shown 5 Remove the front scanner guide rail D 1 spring plate 6 Remove the 2 idle gears E 1 E ring 7 Remove the 3rd scanner motor bracket F 2 screws and 1 connector 8 Replace the 3rd scanner motor G 2 screws A D E F G B C Platen cover or DF Left scale Exposure glass Top cover Rear scale Lens cover Operation panel Left scale bracket Scanner HP sensor bracket FT5535...

Page 127: ...ove the lens vertical drive motor bracket C 2 screws 2 clamps and 1 connector 4 Remove the motor D from the bracket 2 screws Wire installation 1 Place the bead E in the slot F and wind the drive wire four and a half times around the pulley G 2 Wrap the wire around the wire pulley H and attach the spring A to the bracket A E F G H B B C D FSM 5 11 FT5535 4527 4522 ...

Page 128: ...older B and í pull down the lock lever C ó Then slide out the bottle holder assembly D and ú swing out the bottle holder assembly 5 Remove the knob screw E and disconnect the connector F 6 Press down the development unit lock lever G and pull out the development unit H Then place it on a clean sheet of paper Rev 7 95 G H F E D C B A FT5535 4527 4522 5 12 FSM ...

Page 129: ...A and separate the toner supply unit B from the development unit 2 screws 3 Turn over the development unit and empty all the developer C onto the sheet D Make sure that no developer remains on the development roller or in the unit NOTE Dispose of the used developer in accordance with local regulations I H A B C D E G F FSM 5 13 FT5535 4527 4522 ...

Page 130: ...he toner supply unit on the development unit 2 screws and reconnect the connector NOTE Make sure that the positioning rib H sits in the groove I 6 Install the development unit in the copier 1 knob screw and 1 connector 7 Turn on the main switch then perform the TD sensor initial setting for new developer using SP2 214 CAUTION Never make any copy with the new developer before completing the TD sens...

Page 131: ...nd 1 spring 5 Remove the bottle rotating cover B by releasing the three hooks 6 Remove the hinge bracket C from the bottle holder 1 C ring 7 Remove the bottom cover D 3 screws 8 Remove the toner supply motor bracket E 1 screw and replace the toner supply motor F 1 E ring and 1 gear shaft NOTE When reinstalling the hinge bracket on the bottle holder make sure that the roller G slides into the notch...

Page 132: ...sfer belt unit 3 Remove the knob screw B 4 Remove the drum unit C NOTE 1 Insert a clean sheet of paper between the drum and the drum charge roller and wrap the drum up with the paper Doing so prevents the drum charge roller from sticking to the drum Also the paper protects the drum from light fatigue 2 Place the drum unit on a clean sheet of paper A C B FT5535 4527 4522 5 16 FSM ...

Page 133: ...e the bearing D 1 screw E from the old drum and install it on the new drum Also remove the protective sheet from the new drum 6 Set the new drum F in the unit and install the bearing holder again 2 screws NOTE 1 When setting the drum in the unit be careful not to strike it against the rail 2 Do not bend the bearing holder Make sure the bearing holder is in contact with the bearing as they are both...

Page 134: ... against the drum Then rotate the drum clockwise with the screwdriver E Check whether the drum rotates smoothly without catching the blade if it does not repeat steps 7 to 9 10 Reinstall the drum charge roller ass y on the drum unit 2 screws 1 connector NOTE Before reinstalling the drum charge roller assy on the drum unit be sure that no setting powder remains on the drum If setting powder gets on...

Page 135: ... Remove the gear A one E ring 3 Remove the recycled toner transport coil ass y B 2 screws 4 Remove the shaft C one E ring and two gears 5 Remove the pick off pawl ass y D while sliding it sideways 6 Remove the pick off pawls E one shaft F C A B E D E F FSM 5 19 FT5535 4527 4522 ...

Page 136: ...onnect the connector B 4 Pull the ID sensor board C sideways and remove the end D from the ID sensor board holder E 5 Remove the other end of ID sensor board F from the holder G while rolling the ID sensor board in the direction of the arrow as shown in the diagram 6 Remove the ID sensor board A B D E C F G FT5535 4527 4522 5 20 FSM ...

Page 137: ...ade release lever B to release the cleaning blade holder C 4 Remove the old cleaning blade D 2 screws 5 Install the new cleaning blade E 2 screws NOTE 1 Check that there is no dust on the edge of the new cleaning blade 2 When installing the new cleaning blade be sure not to deform the sponge seal F at both sides of the cleaning blade holder D C A B E F F Good No good Good No good FSM 5 21 FT5535 4...

Page 138: ...m Then rotate the drum clockwise with the screwdriver B Check whether the drum rotates smoothly without catching the blade if it does not repeat steps 6 and 7 8 Reinstall the drum charge roller ass y on the drum unit 2 screws 1 connector NOTE Before reinstalling the drum charge roller ass y on the drum unit be sure that no setting powder remains on the drum If setting powder gets onto the drum cha...

Page 139: ...d place a sheet of paper A over the transfer belt NOTE This step prevents the PTL board from damaging the transfer belt if it falls 3 Remove the screw B and push the PTL board C halfway in from the front until its front end does not fall down 4 Remove the PTL board C from the back of the copier A B C FSM 5 23 FT5535 4527 4522 ...

Page 140: ...nsfer belt NOTE This step prevents the quenching lamp from damaging the transfer belt if it falls 3 Disconnect the connector B CN108 from the main board 4 Remove the screw C and push the quenching lamp D halfway in from the front until its front end does not fall down 5 Remove the quenching lamp D from the back of the copier A C B D FT5535 4527 4522 5 24 FSM ...

Page 141: ... place a sheet of paper A over the transfer belt NOTE This step prevents the erase lamp from damaging the transfer belt if it falls 3 Remove the screw B and push the erase lamp C halfway in from the front until its front end does not fall down 4 Remove the erase lamp C from the back of the copier A B C FSM 5 25 FT5535 4527 4522 ...

Page 142: ...snap ring C 5 Remove the drum charge roller D while sliding the bearing E in the direction of the arrow as shown in the diagram NOTE 1 Never touch the surface of the drum charge roller 2 If there is any dirt on the surface of drum charge roller wipe it off with a dry cloth or a special cloth for the drum charge roller The special cloth is available as a service part A1539004 Never use alcohol or w...

Page 143: ...er touch the surface of the drum charge roller 2 If there is any dirt on the surface of the drum charge roller wipe it off with a dry cloth or a special cloth for the drum charge roller The special cloth is available as a service part A1539004 Never use alcohol or water to clean the drum charge roller 3 When replacing the drum charge roller terminal B replace also the roller terminal C at the same...

Page 144: ...4 11 DRUM CHARGE ROLLER CLEANER REPLACEMENT 1 Remove the drum charge roller ass y 2 Remove the screw A 3 Pull out the drum charge roller cleaner B B A FT5535 4527 4522 5 28 FSM ...

Page 145: ...ver touch the surface of the transfer belt 5 A153 A155 and A156 copiers When reinstalling the transfer belt unit align gear D and opening E A157 A159 and A160 copiers When reinstalling the transfer belt unit align opening F and positioning pin G first Then align gear H and opening I A157 A159 and A160 copiers A C B A153 A155 and A156 copiers E D A B C A153 A155 and A156 copiers G F A157 A159 and A...

Page 146: ...tage terminals C 3 Turn the transfer belt ass y D 90 degrees counterclockwise then raise it and remove it 4 Remove the screws E and turn the belt drive holder F 5 Replace the transfer belt G NOTE Be careful not to bend the high voltage terminal H 6 Position the transfer belt at the center of the belt roller I Both marks J should be visible F H E G E I I J A D C B FT5535 4527 4522 5 30 FSM ...

Page 147: ... cleaning blade 4 Reinstall the transfer belt ass y in the transfer belt unit 5 Apply setting powder B to the transfer belt 6 Rotate the gear C clockwise to apply the setting powder evenly to the edge of the transfer belt cleaning blade 7 Do steps 5 and 6 two or three times NOTE Steps 5 and 6 prevent the transfer belt cleaning blade from catching the transfer belt A C B FSM 5 31 FT5535 4527 4522 ...

Page 148: ...Removal 2 Open the cap A and pour the collected toner slowly onto a sheet of paper so that the toner does not scatter NOTE Never use the collected toner in the transfer belt unit for toner recycling 3 Dispose of the toner in accordance with the local regulations A FT5535 4527 4522 5 32 FSM ...

Page 149: ...ch 6 2 PICK UP FEED AND SEPARATION ROLLERS AND TORQUE LIMITER REPLACEMENT A153 A155 A156 1 Remove the upper paper feed tray A or lower paper feed tray B 4 screws for each paper feed tray 2 Remove the pick up C and feed D rollers torque limiter E and the separation roller F 1 clip each NOTE After reinstalling the paper feed tray perform the side to side registration adjustment see Side to side Regi...

Page 150: ...front cover see Outer Cover Removal 4 Remove the right inner cover see Inner Cover Removal 5 Remove the LCT set block B 1 screw 6 Remove the lower paper feed clutch C 1 E ring 7 Remove the separation roller gear D 1 E ring 8 Remove the spring E and remove the timing belt F from the relay roller pulley G 9 Remove the vertical transport guide plate H 1 screw 10 Remove the paper feed unit I 2 screws ...

Page 151: ...main control board unit A 4 screws all connectors 3 Remove the bracket B 2 screws 4 Remove the relay clutch C 1 connector 1 bushing 5 Remove the upper paper feed clutch D 1 E ring 1 connector 6 Remove the separation roller drive gear E 1 E ring 7 Remove the upper paper feed unit F 2 screws 1 connector F C A B D E FSM 5 35 FT5535 4527 4522 ...

Page 152: ...r D NOTE 1 When installing the feed roller assembly the flat side of the roller should be facing down 2 The two rollers without rubber should be at the center of the shaft 3 The factory set roller position is a 4 Roller position b is only used in Japanese models 4 Roller position c is especially useful for B size paper When paper jam or non feed occurs often with B size paper change the feed rolle...

Page 153: ...r Cover Removal 2 Remove the lower right inner cover see Inner Cover Removal 3 Remove the transfer belt assembly see Transfer Belt Unit Removal 4 Remove the registration sensor bracket A 1 screw 1 connector 5 Remove the registration sensor B B A FSM 5 37 FT5535 4527 4522 ...

Page 154: ...ssembly see Paper Feed Roller Replacement 2 Remove the rear cover see Outer Cover Removal 3 Remove the paper feed clutch assembly A 3 screws 1 connector 4 Remove one E ring B and the pull out the shaft C 5 Remove the paper feed clutch D 1 connector C B D A FT5535 4527 4522 5 38 FSM ...

Page 155: ...e Outer Cover Removal 2 Remove the harness cover A 1 screw 3 Remove the LCT s rear cover B 2 screws 4 Remove the stopper bracket C 1 screw 5 Disconnect five connectors D and remove the harness bushing E 6 Remove the LCT D E A C B FSM 5 39 FT5535 4527 4522 ...

Page 156: ...crew 4 Remove the front cover C 3 screws 5 Remove the grip holding bracket D and grip bracket E 2 screws 6 Remove the belt stoppers F 1 screw each 7 Remove the upper pulley G and LCT drive belt H 1 E ring each NOTE When reinstalling the belt stoppers make sure that the LCT bottom plate is at the bottom G H A F B F H G D E C FT5535 4527 4522 5 40 FSM ...

Page 157: ...7 3 LCT MOTOR REPLACEMENT 1 Remove the LCT see LCT Unit Removal 2 Remove the vertical transport guide A 4 screws 3 Remove the LCT motor B 3 screws 1 connector B A FSM 5 41 FT5535 4527 4522 ...

Page 158: ...fusing unit cover B while pushing the release lever C to the left and pull out the fusing unit until it stops 4 Push the release lever again and remove the fusing unit completely CAUTION Before completely removing the fusing unit support the bottom of the fusing unit Rev 7 95 A B C FT5535 4527 4522 5 42 FSM ...

Page 159: ...older E 1 screw 6 Remove the rear lamp holder F 2 screws 7 Disconnect the lamp connectors G 8 Remove the lower front lamp holder H 1 screw and remove the two lamps I NOTE 1 Do not touch the fusing lamps with bare hands 2 When reinstalling the rear lamp holder make sure that the antistatic brush J contacts the hot roller and pressure roller shown 3 The standard pressure spring position is at the up...

Page 160: ...both ends of the protective sheet on the new one 2 The standard pressure spring position is at the upper position CAUTION The hot rollers for the A153 155 156 are different from the hot rollers for the A157 159 160 To distinguish between the two types of hot roller look at the end of the roller The A153 155 156 roller has three small dot like indentations at one end and the A157 159 160 has two Do...

Page 161: ...sembly B 5 Remove the fusing knob C 6 Replace the pressure roller D 2 C rings 2 bearings 7 Replace the cleaning roller E 2 bushings NOTE 1 When reinstalling the fusing entrance guide tighten the screws while pushing the guide plate up to the upper position for standard or thin paper For thick paper let the entrance guide plate drop to the lowest position 2 The standard pressure spring position is ...

Page 162: ...sure spring position is at the upper position 8 6 THERMOFUSE REPLACEMENT 1 Remove the fusing unit see Fusing Unit Removal 2 Remove the pressure springs and remove the upper fusing unit 4 screws 3 Remove the thermofuse A 2 screws NOTE 1 When replacing the thermofuse make sure that you do not damage the hot roller 2 The standard pressure spring position is at the upper position A FT5535 4527 4522 5 ...

Page 163: ...e separation roller assembly A 2 screws 3 Remove the springs B 4 Remove the friction roller C 2 E rings 2 bushings NOTE This friction roller has a one way clutch Be sure to install the roller so that it rotates in the direction of the arrow see the illustration A B C FSM 5 47 FT5535 4527 4522 ...

Page 164: ...6 Move the bushings F inward and remove the duplex feed roller assembly G 7 Remove the bushing F the paper flattener H 1 E ring the stack roller I the paper flattener J and the duplex feed roller K NOTE When installing the stack roller and the duplex feed roller make sure that they are inserted in the correct orientation as shown B D C A F E G K J H E F I Feed Roller Stack Roller See from the fron...

Page 165: ...ve the upper guide plate B and the lower guide plate C 1 clip 4 Remove the inner cover D 1 screw 5 Remove the inner cover bracket E 1 screw 6 Remove the duplex feed roller assembly F 2 clips 7 Remove the timing belt pulley G and remove the timing belt H 8 Remove the spring I F I H G E D B C A FSM 5 49 FT5535 4527 4522 ...

Page 166: ...y C 3 screws 12 Replace the duplex feed motor D 2 screws NOTE 1 When installing the paper feed assembly make sure that the bottom plate E is on top of the bracket F as shown 2 When installing the paper feed assembly make sure that the mylar G on the bottom plate is on top of the guide plate H as shown C A B E H G H F G E G F FT5535 4527 4522 5 50 FSM ...

Page 167: ...d VL correction data are cleared Therefore after the light intensity adjustment auto ADS gain adjustment SP4 201 and forced VL detection SP3 105 must be performed See Practical SP Mode Use Tables in section 4 for the exact order in which SP modes must be done after changing major components 1 Turn the main switch off 2 Clean the following parts Item No Section Method 1 Optics mirrors lens reflecto...

Page 168: ...ge can be set between 50 and 75 V in 0 5 V steps The default setting is on the SP MODE FACTORY SETTING DATA sheet located in the upper inner cover 3 Leave SP mode and make a copy at manual image density level 4 4 Check whether the image density is correct or not If it is not repeat the above steps from 1 to 3 7 Perform ADS gain adjustment SP4 201 and forced VL detection SP3 105 NOTE If the image d...

Page 169: ...he exposure lamp even across its length CAUTION Unplug the copier before starting the following procedure 1 Clean the optics components 2 Place a test chart on the exposure glass and make an A3 11 x 17 copy 3 If the side to side variation of the gray scales is not within the adjustment standard turn off the main switch and remove the exposure glass see Exposure Glass Removal 4 Position the adjusti...

Page 170: ...opment bias voltage used for copying NOTE Normally the SP2 201 001 setting should be 5 standard Development bias adjustment should be done only when adjusting light intensity SP4 001 after performing the drum initialization SP3 123 if necessary SP 2 201 001 Development Bias Adjustment Setting Density Development Bias Correction Voltage 1 Dark 80V 2 60V 3 40V 4 20V 5 Normal 0V 6 Light 20V 7 40V 8 6...

Page 171: ...at manual ID level 7 How SP2 201 002 changes the development bias voltage for images at manual ID level 7 SP2 201 002 Highlight Bias Setting Density Development Bias Correction Voltage 1 Normal 40V 2 Dark 0V 3 Lighter 80V 4 Lightest 120V 1 Enter SP2 201 002 2 Change the setting displayed in the reduce enlarge indicator with the number keys Determine the new setting from the above table 3 Leave SP2...

Page 172: ...g the VSP pattern SP2 203 VSP Pattern Bias Setting Black Toner Density Image Density Development Bias Voltage for the ID Sensor Pattern 1 Low Light 100V 2 80V 3 60V 4 40V 5 20V 6 Normal Normal 0 7 High Dark 20V 8 40V 9 60V 10 80V 1 Enter SP2 203 2 Change the setting displayed in the reduce enlarge indicator with the numeric keys Determine the new setting from the above table 3 Leave this SP mode F...

Page 173: ...n 1 TD sensor supply mode 2 Fixed supply mode 3 Detect supply mode 10 6 AUTOMATIC ID SENSOR ADJUSTMENT SP3 001 When 1 After cleaning removing or replacing the ID sensor board 2 After replacing the OPC drum or RAM board on the main control board 3 If a toner supply control problem occurs 4 If memory all clear SP5 801 has been performed Purpose To make sure that the ID sensor functions correctly Adj...

Page 174: ... the customer How Detect supply mode SP2 222 TD sensor supply mode SP2 208 002 Fixed supply mode SP2 208 003 All three service programs change the toner supply clutch ON period SP2 222 Toner Supply Ratio Detect Supply Mode Setting 1 2 3 4 Toner Supply Ratio 7 15 30 60 SP2 208 002 Toner Supply Ratio TD Sensor Supply Mode Setting 1 2 3 4 Toner Supply Ratio 7 15 30 60 SP2 208 003 Toner Supply Ratio F...

Page 175: ... in memory to get the correct sensor output NOTE Close the platen cover to prevent external light from reaching the ADS sensor when performing this adjustment The adjusted ADS gain value and the sensor output can be monitored with SP4 202 Refer to the SP mode table for details 10 9 ADS DENSITY SELECTION SP5 106 When If copies are too light or dirty background appears on copies in ADS mode Purpose ...

Page 176: ...tical magnification is within the adjustment standard 4 If vertical magnification is not correct go through the following steps 1 Enter SP4 008 2 Change the vertical magnification setting displayed in the reduce enlarge indicator Use the number keys and follow these rules If the copy image is too short increase the setting If the copy image is too long decrease the setting NOTE SP4 008 can be set ...

Page 177: ... horizontal magnification is within the adjustment standard 4 If horizontal magnification is not correct go through the following steps 1 Enter SP4 101 2 Change the horizontal magnification setting displayed in the three digit indicator Use the number keys and follow these rules If the copy image is too short increase the setting If the copy image is too long decrease the setting NOTE SP4 101 can ...

Page 178: ...01 horizontal magnification and SP4 103 focus adjustment in full size Purpose To maintain correct focus in enlarge reduce mode How SP4 102 changes the lens position 0 1 per step in enlarge reduce mode NOTE Normally the factory set value is best for this adjustment Refer to SP MODE FACTORY SETTING DATA sheet located in the upper inner cover SP4 102 Lens Error Correction 0 16 default 8 0 8 to 0 8 10...

Page 179: ...ations Adjustment standard 0 2 mm 0 0 08 How SP4 011 001 009 changes the lens horizontal home position SP4 011 001 007 and 009 change the lens horizontal home position used for certain units see step 3 below If registration is not within the standard when using a certain unit use one of these SP modes SP4 011 008 is the base adjustment made in the factory If this setting is changed by a small amou...

Page 180: ...ray 3rd Tray 005 5th Tray 4th Tray 006 By pass By pass 007 LCT LCT 008 Base setting made in the factory 009 ADF ADF 3 Change the side to side registration setting displayed in the reduce enlarge indicator Use the number keys and follow these rules If the copy image is shifted to front increase the setting If the copy image is shifted to rear decrease the setting 4 Leave SP mode 5 Check whether sid...

Page 181: ...r perform this adjustment unless you have positively verified that the source of the image skewing is optical and not in the paper path 1 Turn off the main switch and remove the exposure glass 2 Peel off the shielding mylar A halfway 3 Adjust the 4th 5th mirror height by turning the adjusting screw B NOTE After the adjustment stick the mylar A again in its former position Rev 7 95 B A FSM 5 65 FT5...

Page 182: ...etallic object If the battery is short circuited RAM data will be destroyed in the worst case 1 Turn off the main switch and unplug the power cord 2 Remove the rear cover 3 Remove the main control board A 4 screws and all connectors 4 Remove the RAM board B from the old main control board and install it on the new board A B FT5535 4527 4522 5 66 FSM ...

Page 183: ...hat the ac drive board is defective 2 Do not adjust VR371 on the ac drive board Copy quality will be seriously affected if it is turned 1 Turn off the main switch and unplug the machine 2 Remove the rear cover 3 Replace the ac drive board A 1 screw 3 locking supports and all connectors A FSM 5 67 FT5535 4527 4522 ...

Page 184: ... FU304 on the board before determining that the dc power supply board is defective 1 Turn off the main switch and unplug the machine 2 Remove the rear cover 3 Replace the dc power supply board A 7 screws and all connectors NOTE 6 screws for 115V machines A FT5535 4527 4522 5 68 FSM ...

Page 185: ...Y BOARD REPLACEMENT 1 Turn off the main switch and unplug the machine 2 Remove the rear cover 3 Remove the main control board 4 Replace the CB high voltage supply board A 2 screws and 1 locking support FSM 5 69 FT5535 4527 4522 ...

Page 186: ...ACEMENT 1 Turn off the main switch and unplug the machine 2 Remove the transfer belt unit A See Transfer Belt Unit Removal 3 Replace the T high voltage supply board B 1 screw 1 clamp and 2 metal spring plates A B FT5535 4527 4522 5 70 FSM ...

Page 187: ...SECTION 6 TROUBLESHOOTING ...

Page 188: ...ting information based on reports from you and other field service engineers around the world 1 The following is a comparison table showing the area you should check first if you have image problems at periodic intervals Interval of Periodic Image Problem Possible Cause 188 4 mm 7 42 Drum 43 9 mm 1 73 Drum Charge Roller 334 mm 13 15 A153 A155 and A156 copiers 244 5 mm 9 63 A157 A159 and A160 copie...

Page 189: ... paper T high voltage supply board failure Poor high voltage lead wire contact Damaged transfer belt 3 The development roller does not rotate Broken drive gears Defective development unit drive clutch Broken transfer belt contact clutch 4 Poor drum sensitivity The drum was exposed to fluorescent light or direct sunlight for long period of time The drum was exposed to ammonia gas or corrosive fumes...

Page 190: ...nal Is the drum charge roller broken No Yes Replace the drum charge roller Are the development drive gears worn or broken No Yes Replace the drive gears Does the development unit drive clutch turn on properly Yes No Does the voltage at CN117 4 stay at 24 volts on the main board after the Start key is pressed 24 volts 0 volts Replace the development unit drive clutch Replace the main control board ...

Page 191: ...er even if the signal changes to a 5V pulse signal replace the CB high voltage supply board CN105 2 Transfer PWM 1 If the signal stays LOW after the Start key is pressed replace the main control board 2 If no transfer voltage is applied to the transfer belt unit even if the signal changes to a 5V pulse signal replace the T high voltage supply board If there is no problem with the signal lines repl...

Page 192: ...e Poor development bias terminal contact The development bias is grounded 3 The OPC drum is not grounded properly 4 ADS mode Improper ADS Density setting SP5 106 ADS Sensor board failure CB high voltage supply board failure Incorrect adjustment of the ADS sensor SP4 201 Sensitivity of the ADS sensor is not correct for the original 5 High toner density Improper setting of the drum charge voltage ad...

Page 193: ...charge roller thermistor connector connected properly Yes No Connect the drum charge roller thermistor connector Replace the drum charge thermistor Are both the following conditions true a Is the auto process contol mode se lection SP3 801 set to ON b Is initial VLP VLG SP3 106 not 0 Yes No Clean the optics and adjust the exposure lamp voltage SP4 001 Perform ADS initial setting SP4 201 and forced...

Page 194: ...not charge Is the background of the copy image still dirty No Yes If dirty background still appears is the development bias applied to the development roller shaft No Yes Check that the drum is properly grounded Check the continuity between the development roller shaft and the development bias terminal Good No good Repair the harness or terminals Is the signal at CN115 1 a 5V pulse signal after th...

Page 195: ...ackground occurs only in ADS mode do the following If the ADS voltage SP4 202 is not within 2 7 0 1 volts this is the standard voltage readjust the ADS voltage SP4 201 Change the ADS density setting SP5 106 from 1 Normal to 2 Light If dirty background occurs only for some types of red paper originals in ADS mode do the following Change the ADS sensor to the optional ADS sensor which has different ...

Page 196: ...ion Does the uneven image area shift when a reduction copy is made No Yes Is the optics section dirty No Yes Clean the optics Adjust the exposure adjustment plates on the 1st scanner See Uneven Exposure Adjustment in the Replacement and Adjustment section Is the erase lamp quenching lamp or toner shield glass dirty No Yes Clean the erase lamp quenching lamp or toner shield glass Clean or replace t...

Page 197: ...uction copy is made No Yes Check and clean the optics section including the toner shield glass Press the blade release lever several times to clean the edge of the cleaning blade If black bands still appear go to the next step Is the edge of the cleaning blade deformed No Yes Replace the cleaning blade Is the drum charge roller dirty No Yes Clean or replace the drum charge roller If the inlet seal...

Page 198: ... the cleaning blade scratched No Yes Replace the cleaning blade Is the hot roller scratched No Yes Check whether black lines appear on the copy by stopping the copy paper in the transport section If no black lines appear replace the hot roller Check whether the drum is scratched or there is built up toner on the drum If toner is built up on the drum clean the drum as follows NOTE Never use alcohol...

Page 199: ... 2 Damp or deformed inlet seal on the development unit Action Is the drum charge roller dirty No Yes Clean the drum charge roller with a dry cloth Is the inlet seal damp or deformed No Yes Clean the inlet seal with a dry cloth If the problem is not corrected replace the inlet seal plate and the seal as a set Replace the drum charge roller FT5535 4527 4522 6 12 FSM ...

Page 200: ...elease lever several times Make a copy and if white lines still appear go to the next step Make a copy and stop the machine when the paper reaches the transport sec tion Do white lines appear on the copy No Yes Replace the drum if it is scratched Replace the hot roller if it is scratched NOTE If the drum is scratched find out what caused the scratches on the drum and correct the problem It could b...

Page 201: ...r 3 The hot roller is scratched If black lines appear at 125 6 mm 4 94 intervals the cause is a scratched hot roller 4 Toner adheres to the drum surface Due to insufficient cleaning foreign matter may accumulate on the blade causing toner to stick to the drum surface when the drum stops Action Is the drum scratched No Yes Replace the drum Is the drum charge roller scratched No Yes Replace the drum...

Page 202: ...nd 2nd scanners 3 The mirrors are in the wrong position 4 The stubs of the 3rd scanner are off the rails Action Are the 1st and 2nd scanners properly positioned Yes No Reposition the scanners correctly Is each mirror positioned correctly on its scanner Yes No Reposition the mirror correctly If the spring plates are defective replace them Are the stubs of the 3rd scanner assembly off the rails No Y...

Page 203: ...ive 4 The VSP pattern development bias is too high 5 The drum charge voltage for making VSP patterns is too low Action Check the values of VSP and VSG with SP3 103 001 and SP3 103 002 respectively Clean the ID sensor and around the drum including the development unit Adjust the ID sensor with SP3 001 Can the ID sensor be adjusted correctly Yes No Refer to the section dealing with SC351 Enter SP3 1...

Page 204: ...ont cover Yes No If the CB high voltage supply board is the original one store the factory setting in SP2 003 If it is not then store 16 in SP2 003 Is the copier in fixed supply mode No Yes Change the setting of SP2 208 001 to 3 Reduce the value of the development bias correction for making VSP patterns SP2 203 to make the VSP pattern darker Note The toner supply clutch should turn on for about a ...

Page 205: ...he VSP pattern bias is too low 5 The drum charge voltage for making VSP patterns is too high Action Check the values of VSP and VSG with SP3 103 001 and SP3 103 002 respectively Clean the ID sensor and around the drum Adjust the ID sensor with SP3 001 Can the ID sensor be adjusted correctly Yes No Refer to the section that deals with SC351 Perform forced toner supply SP2 207 until VSP is at about ...

Page 206: ...eplace the toner bottle drive motor Replace the main control board Is the drum charge voltage correction value for the VSP pattern SP2 003 cor rectly set No If the CB high voltage supply board is the original one store the factory setting in SP2 003 If it is not then store 16 in SP2 003 Is the copier in fixed supply mode No Yes Change the setting of SP2 208 001 to 3 Increase the value of the devel...

Page 207: ...sity is too high 2 The inlet seal on the development unit is out of position 3 The developer has deteriorated Action Is the toner density too high No Yes See section 1 11 Toner Density Too High Is the inlet seal deformed No Yes Replace the inlet seal plate Replace the developer FT5535 4527 4522 6 20 FSM ...

Page 208: ...e is too low 3 The thermistor is malfunctioning Action Adjust the position of the pressure springs to increase the fusing pressure No good Increase the fusing temperature using SP1 105 001 main fusing lamp and SP 105 003 secondary fusing lamp No good Check the thermistor If the thermistor is malfunctioning replace it FSM 6 21 FT5535 4527 4522 ...

Page 209: ...6 CREASING AFTER FUSING Problem Under high humidity conditions humidified copy paper creases as it comes out of the fusing unit Action Install an optional tray heater in each paper feeding station Refer to Tray Heater Installation in section 3 The tray heater is available as a service part 3 17 Z FOLDED COPY OR LEADING EDGE REGISTRATION VARIES Problem Copies are folded into a Z shape at the leadin...

Page 210: ...7 Defective TD sensor Action Is the ID sensor initial setting SP3 002 within the 4 0 0 2 V range Yes No Perform ID sensor initial setting SP3 001 Is the ID sensor initial setting SP3 002 within the 4 0 0 2 V range Yes No Check whether the ID sensor board terminal contacts the connector at the rear of the copier well or not Good No Good Clean the ID sensor board terminal and make it contact the sen...

Page 211: ...o is VSP VSG 0 1 Yes No Make 10 or more copies Is VSG SP3 103 002 within the 4 0 0 2 V range Also is VSP VSG 0 1 Yes No Replace the ID sensor board Is the TD sensor initial setting SP2 220 within the 2 5 0 1 V range Yes No Is the TD sensor connector connected properly Yes No Connect the TD sensor connector Replace the developer and do the TD sensor initial setting SP2 214 FT5535 4527 4522 6 24 FSM...

Page 212: ...hin the 2 5 0 1 V range Yes No Replace the TD sensor Is the TD sensor output SP2 215 001 between 0 3 and 4 0 V Yes No Replace the TD sensor Set the toner supply mode to Detect Supply Mode To do this set SP2 208 001 to 3 FSM 6 25 FT5535 4527 4522 ...

Page 213: ... can be operated as usual NOTE For safety reasons Level A service calls cannot be cleared by turning the main switch off on The following procedure must be performed to clear these service call conditions after servicing the machine 1 Turn on the main switch 2 Enter SP5 810 SC code reset and press the Enter key 3 Exit SP mode and turn the main switch off and on 3 2 SC CODE TABLE This table summari...

Page 214: ... Duplex tray end fence jogger h p sensor error 1 C E523 Duplex tray end fence jogger h p sensor error 2 C E524 Duplex tray side fence jogger h p sensor error 1 C E525 Duplex tray side fence jogger h p sensor error 2 C E541 Fusing unit thermistor open A E542 Fusing temperature warm up error A E543 Fusing overheat A E544 Fusing overheat A E547 Continuous fusing lamp ON condition A E548 Fusing ready ...

Page 215: ...ected Duplex mode 6 E523 Duplex tray end fence HP not OFF When duplex mode is selected Duplex mode 6 E524 Duplex side fence jogger HP not ON When duplex mode is selected Duplex mode 6 E525 Duplex side fence jogger HP not OFF When duplex mode is selected Duplex mode 6 E620 Main board ADF communication error When an original is set on the ADF ADF mode 7 E623 Main board Paper tray unit communication ...

Page 216: ...n Cover open Close the LCT cover C5 Sorter cover open or sorter not set Close sorter cover or set the sorter C6 ADF cover open Cover open Close the ADF cover C7 Right cover open Close the right side of main copier unit 3 5 U CODE TABLE U code Condition Message on LCD A156 copier only U2 Key counter not set Insert a key counter or enabling device Enter a user code U6 Fusing unit not set Open the fr...

Page 217: ...r home position error 1 Definition B The scanner home position sensor remains de actuated for 7 5 seconds after the scanners start moving from the return position Possible causes Scanner home position sensor failure CN114 on the main board not connected correctly Incorrect scanner wire position E121 Scanner home position error 2 Definition B The scanner home position sensor remains actuated for 0 ...

Page 218: ...e DC power supply board defective check FU303 E141 Lens vertical home position sensor error 2 Definition B The lens vertical home position sensor remains actuated 2 0 seconds after the lens left the home position Possible Causes Lens vertical home position sensor defective Lens vertical drive motor defective CN116 on the main control board is not connected correctly DC power supply board defective...

Page 219: ...r 1 Definition B The 3rd scanner home position sensor remains de activated 1 0 second after the 3rd scanner starts returning to the home position Possible Causes 3rd scanner home position sensor defective 3rd scanner drive motor defective DC power supply board defective check FU303 E145 3rd scanner home position sensor error 2 Definition B The 3rd scanner home position sensor remains actuated 3 7 ...

Page 220: ...ent leak Definition B A charge current leak signal is detected Possible Causes Drum charge roller unit defective CB high voltage supply board defective E346 Development bias leak Definition B A development bias leak signal is detected Possible Causes Sleeve roller receptacle damage CB high voltage supply board defective E351 ID sensor adjustment error Definition D When the ID sensor output VSG fal...

Page 221: ...d VSP goes above 2 5 volts Possible Causes Dirty ID sensor ID sensor board defective Main control board defective E354 VSG abnormal Definition D Detected VSG is equal to or is below 2 5 volts Possible Causes Dirty ID sensor ID sensor board defective Main control board defective E355 TD sensor upper limit detection abnormal Definition D TD sensor output exceeds 4 0 volts during copy cycles Possible...

Page 222: ...Causes Transfer belt contact home position sensor defective Transfer belt contact clutch defective Main control board defective E440 Main motor lock Definition B A main motor lock signal is detected Possible Causes Too much load on the drive mechanism Main motor defective or poor connection Main motor control board defective Main control board defective E442 Drum charge thermistor abnormal Definit...

Page 223: ... 10 0 seconds Possible Causes Upper limit sensor defective Tray lift motor defective Main control board defective E506 Paper tray unit main motor lock A549 A550 A553 optional paper tray unit only Definition C A paper tray unit main motor lock signal is detected Possible Causes Paper tray unit main motor defective Interface board defective Main control board defective E507 LCT lift motor abnormal A...

Page 224: ...home position sensor remains actuated for 1 0 second when the jogger home position initialization procedure is performed Possible Causes End fence jogger home position sensor defective End fence jogger motor defective Duplex control board defective Main control board defective E524 Side fence jogger home position sensor error 1 A156 A160 only Definition C The side fence jogger home position sensor...

Page 225: ...ponding to 0 C Possible Causes Fusing thermistor open Main control board defective Fusing lamp open E542 Fusing temperature warm up error Definition A The fusing temperature does not reach the ready temperature within 3 0 minutes after the main switch is turned on Possible Causes Fusing thermistor defective or out of position Fusing lamp open Fusing thermofuse open AC drive board defective check t...

Page 226: ...d by condition after warm up is completed Possible Causes Fusing thermistor defective E548 Fusing ready temperature abnormal Definition A The fusing temperature goes 40 C below or 40 C over the stand by temperature after warm up is completed Possible Causes Fusing thermistor connector not connected properly E620 Communication error between main control board and ARDF Definition C The main CPU cann...

Page 227: ...rd and the paper tray unit Main control board defective Paper tray unit interface board defective E720 Timing Sensor Roller Drive Output Error A554 A555 Definition B When the roller drive transport motor is turning the timing sensor takes over 500 ms to change Possible Causes The timing sensor is defective The rroller drive transport motor is defective The main control board is defective E721 Timi...

Page 228: ... Sensor Output Error A554 A555 Definition C When the grip motor rotates the grip home position sensor takes over 0 2 s to be deactivated When the grip motor rotates in reverse the grip home position sensor takes over 2 5 s to be deactivated Possible Causes The grip home position sensor is defective The grip motor is defective The main control board is defective E724 Stapler Error A554 A555 Definit...

Page 229: ...er does not turn on Possible Causes Total counter defective CN121 on the main control board not connected correctly E901 Total counter error 2 Definition B The total counter does not turn off Possible Causes Total counter defective FT5535 4527 4522 6 42 FSM ...

Page 230: ...t location A when the Print key is pressed FU303 6 3 A 125 V 6 3 A 250 V 24V VAA2 E140 E141 E142 E143 E144 or E145 lights depending on the peripherals that are attached to the copier FU304 6 3 A 125 V 6 3 A 250 V 24V VAA3 C5 lights on machines that have a sorter installed Also the DF does not communicate with the copier the DF stays off AC Drive Board for 115 V machines only FU371 15 A 125 V 115VA...

Page 231: ...Upper Tray Upper Limit A153 A155 machines only S5 131 8 Open The Paper End indicator lights even if there is paper on the tray Shorted The tray bottom plate locks at the upper position Lower Tray Paper End S6 134 2 Open The Paper End indicator lights even if paper is present Shorted The Paper End indicator does not light even if there is no paper Lower Relay S7 Misfeed detect 128 1 Open A paper ja...

Page 232: ... E145 is displayed Original Length 2 S19 118 7 Open The CPU cannot detect the original size properly APS and ARE do not function correctly Shorted Fusing Exit S20 Misfeed detect 109 2 Open A paper jam type B occurs whenever a copy is made Shorted The Paper Jam B indicator lights even if there is no paper Platen Cover S21 113 4 Open APS and ARE do not function properly Shorted No symptom Toner End ...

Page 233: ...s Left In The Duplex Tray is displayed or the Paper Jam Z indicator lights even if there is no paper in the duplex tray Duplex Entrance Duplex machines only S30 Misfeed detect 140 10 Open Copies Left In The Duplex Tray is displayed or the Paper Jam Z indicator lights even if there is no paper in the duplex tray Shorted The Paper Jam C indicator lights even if there is no paper Side Fence Jogger HP...

Page 234: ...r Size SW6 137 3 7 Open The CPU cannot detect the proper paper size and misfeeds may occur when a copy is made Shorted Vertical Guide Set Non LCT machines only SW7 127 8 Open The power goes down when the vertical guide is opened Shorted The copier does not turn on LCT Cover 1 LCT machines only SW8 132 11 Open The LCT bottom plate lowers even if there is paper in the LCT Shorted The LCT bottom plat...

Page 235: ...SECTION 7 DF61 AUTO REVERSE DOCUMENT FEEDER Machine Code A548 ...

Page 236: ...51 2 x 81 2 Weight 52 105 14 27 lb Original Feed Automatic feed ADF mode Manual feed one by one SADF mode Auto Reverse Feed ARDF mode Original Table Capacity 50 sheets at 80 g m2 21 lb Original Placement Face up first sheet on top Original Separation Feed Roller and Friction Belt Original Transport One flat belt Power Consumption 45 W Power Source 24 V 10 from the copier 1 8 A Dimensions W x D x H...

Page 237: ...NENTS 1 Original Stopper 2 Press Lever 3 Original Table 4 Exit Rollers 5 Inverter Pawls 6 Inverter Rollers 7 Transport Belt 8 Pick up Rollers 9 Pull out Roller 10 Feed Roller 11 Friction Belt 1 2 5 4 3 7 6 8 11 10 9 FT5535 4527 4522 7 2 FSM ...

Page 238: ...r 6 Belt Drive Motor 7 DF Main Board 8 Inverter Solenoid 9 Feed out Cover Open Sensor 10 Feed out Motor 11 Feed out Sensor 12 APS Start Sensor 13 DF Position Sensor 14 Original Width Sensor 1 15 Original Width Sensor 2 16 Original Width Sensor 3 17 Registration Sensor 17 13 14 15 16 12 11 10 9 7 6 5 4 3 2 1 8 FSM 7 3 FT5535 4527 4522 ...

Page 239: ...t it is time to detect the original size in platen mode 12 S6 DF Position Informs the CPU whether the DF is in the up or down position 13 S7 Original Width 1 Detects the width of the original 14 S8 Original Width 2 Detects the width of the original 15 S9 Original Width 3 Detects the width of the original 16 S10 Registration Determines original stop timing and measures the length of the original 17...

Page 240: ... quantity and condition of the accessories in the box against the following list 1 New Equipment Condition Report 1 2 Installation Procedure 1 3 Stud Screw 2 4 Philips Screw with Flat Washer M4 x 10 2 5 Sponge Retainer 1 FSM 7 5 FT5535 4527 4522 ...

Page 241: ... front as shown NOTE When mounting the ARDF hold it by hand as shown in the illustration Holding it in another way may damage the ARDF 5 Screw the two M4 x 10 screws E into the holes F and tighten them 6 Remove the Plug P from the rear of the copier 7 Connect the connectors G into the socket on the rear of the copier 8 All models except for the A156 Attach the symbol explanation decal H and the co...

Page 242: ...ith paper 25 cpm 0 0 1 1 Two sided mode free run with paper 25 cpm 1 0 1 1 Not used 1 1 0 1 Solenoid test 0 1 1 0 Motor test 1 1 1 0 Combine two originals mode free run with paper 0 0 0 1 Not used 0 1 1 1 Not used 1 1 1 1 Indicators On NOTE a Paper will automatically feed after 3 seconds when the with paper free run modes are selected b To prevent the friction belt from wearing open the feed in co...

Page 243: ...he registration in one sided thin original mode 102 Adjusts the registration in two sided original mode 5 3 LED LED No Function 101 Monitors the communication with the copier 5 4 FUSE FUSE No Function 101 Protects the 24 V line FT5535 4527 4522 7 8 FSM ...

Page 244: ...belt assembly B NOTE Remove the two lower screws C first 4 Bend the transport belt assembly and pull out the transport belt D as shown NOTE a When installing the transport belt make sure that the belt runs under the belt guide spacers E b When securing the transport belt assembly with the 6 screws make sure to secure the four upper screws first A B C D E FSM 7 9 FT5535 4527 4522 ...

Page 245: ...nd open the feed in cover A 2 Remove the feed roller assembly B by pulling it towards the front 3 Replace the feed roller NOTE When installing the feed roller assembly make sure the pins C D on both sides are fixed properly B D C A FT5535 4527 4522 7 10 FSM ...

Page 246: ...ON BELT REPLACEMENT 1 Turn off the main switch and open the feed in cover A 2 Gently pull up the friction belt assembly B and remove it from the shaft 3 Replace the friction belt C A B C FSM 7 11 FT5535 4527 4522 ...

Page 247: ...g B 4 Remove the stopper pressure lever shaft C 2 E rings 5 Remove both front D and rear E feed in cover magnet catches 1 screw each 6 Remove the feed in guide plate F 4 screws 7 Remove the original set sensor assembly G 1 screw 8 Remove the original width sensor assembly H 1 screw 9 Replace the required sensor A B C F D E G H FT5535 4527 4522 7 12 FSM ...

Page 248: ...iginal table The paper will feed automatically 4 After the original stops on the exposure glass raise the DF carefully so that the original does not move 5 Check that the gap between the trailing edge of the paper and the left original scale B is 0 2 5 mm 6 If the gap is not within this specification adjust the registration with VR101 C Turning VR101 counter clockwise will increase the gap Fine Ad...

Page 249: ...he paper will feed automatically 5 After the original stops on the exposure glass raise the DF carefully so that the original does not move 6 Check that the gap between the trailing left edge of the paper and the left edge of the original rear scale D is 10 2 mm 7 If the gap is not within this specification adjust the registration with VR102 C Turning VR102 counter clockwise will increase the gap ...

Page 250: ... x 11 sideways paper 64 g m2 17 lb on the original table and press the Print key 2 After the original stops on the exposure glass raise the DF carefully so that the original does not move 3 Check if the gap between the rear edge of the paper and the rear original scale is within the specification listed above 4 If it is out of specification reposition the 2 screws A securing the DF hinge to the lo...

Page 251: ...SECTION 8 PS290 280 PAPER TRAY UNIT Machine Code A549 550 ...

Page 252: ...ity Approximately 500 sheets Paper Feed Speed 20 40 copies minute A4 81 2 X11 sideways Power Source DC 24V 5V and AC 120V 220 240V from the main machine Power Consumption Maximum 110 5 W Average 50 W Dimensions 620 mm 24 4 width X 632 mm 24 9 depth X 390 mm 15 4 height Weight Less than 36 kg 79 4 lb Two tray type Less than 38 kg 83 8 lb Three tray type FSM 8 1 FT5535 4527 4522 ...

Page 253: ...AL COMPONENT LAYOUT 1 Paper Tray 1 2 Pick up Roller 3 Paper Feed Roller 4 Relay Rollers 5 Reverse Roller 6 Lower Right Door 7 Paper Lift Motors 8 Paper Tray 3 A549 model only 9 Paper Tray 2 1 2 3 4 5 6 7 8 9 FT5535 4527 4522 8 2 FSM ...

Page 254: ... 1 Vertical Transport Roller Gears 2 Paper Feed Clutch 1 3 Paper Feed Clutch 2 4 Separation Roller Gears 5 Paper Feed Clutch 3 6 Main Motor 7 Relay Clutch 8 Timing Pulley 1 2 1 3 4 5 6 7 8 4 4 FSM 8 3 FT5535 4527 4522 ...

Page 255: ...d and jam detection timing S5 23 Relay 2 S6 20 Relay 3 S7 28 Paper end 1 Detects when the paper tray is empty S8 24 Paper end 2 S9 21 Paper end 3 A549 only Switches SW1 22 Tray cover Detects whether the tray unit cover is open and cuts the 24 Vdc power if it is SW2 3 Tray set 1 Detects whether the paper tray is in place SW3 4 Tray set 2 SW4 6 Tray set 3 A549 only Magnetic clutches CL1 9 Paper feed...

Page 256: ... condition of the accessories in the box against the following list 1 Right Support Bracket 1 2 Left Support Bracket 1 3 Joint Bracket 1 4 Shoulder Screw 1 5 Screw M4 x 8 4 6 New Equipment Condition Report 1 7 Installation Procedure 1 FSM 8 5 FT5535 4527 4522 ...

Page 257: ...ing retainers after installing the machine They will be reused if the machine is transported to another location in the future Proper reinstallation of the shipping retainers is required in order to avoid any transport damage 1 Remove the strips of tape 2 Remove the bottom plate stopper A Rev 6 95 A FT5535 4527 4522 8 6 FSM ...

Page 258: ...TION If you do not do this the machine may fall forwards if all the paper trays are pulled open 9 Pull out the paper tray and load paper into it The paper size and direction for each tray should be designated by a customer The side and rear fences should be properly positioned 10 Turn on the main switch 11 Enter the proper paper size for each paper tray by following the instructions in the copier ...

Page 259: ...the tray heaters E 2 screws each 4 Install the clamper F and clamp the heater harnesses 5 Install the heater bracket G 2 screws 6 Connect the heater harnesses 7 Install the clamper H and clamp the heater harnesses NOTE After replacing the paper tray perform the side to side registration adjustment see Removal and Adjustment in the manual for the copier E F A D Three tray type F E A C B Two tray ty...

Page 260: ...type Free Run Mode 2 Paper feed tray 3 only On Off Free Run Mode 2 On On Free Run Mode 1 Do not touch dip switches 1 to 5 How to do a free run 1 Select either mode 1 or mode 2 with dip switches 6 and 7 2 Turn off the power disconnect the optical cable and turn on the power 3 Press SW101 on the PCB to start the free run 4 When you wish to stop the free run press SW102 on the PCB and return the dip ...

Page 261: ...4 2 TEST POINTS NUMBER FUNCTION TP101 5V TP102 24V TP103 GND TP104 TXD Transmit signal TP105 RXD Receive signal TP106 GND FT5535 4527 4522 8 10 FSM ...

Page 262: ...ve the front lower cover 2 screws Right Front Cover C 1 Remove the front lower cover B 2 Remove the right front cover 2 screws Right Rear Cover D 1 Remove the rear cover A 2 Remove the right rear cover 2 screws Left Cover E 1 Remove the rear cover A 2 Remove the front lower cover B 3 Remove the left cover 4 screws E A D C B FSM 8 11 FT5535 4527 4522 ...

Page 263: ...move the timing belt A 3 Remove the drive unit B 2 screws 2 connectors 4 Remove the separation roller gear C 5 Remove the paper feed clutch D 1 connector NOTE When reinstalling the clutch make sure that the clutch stopper groove engages the stopper bracket A B C D FT5535 4527 4522 8 12 FSM ...

Page 264: ...ver Removal 5 Remove the front right cover B 2 screws 6 Remove the paper feed unit C 2 screws for each unit NOTE When removing the paper feed unit do the following When removing the paper feed roller gear remove the rubber foot D Remove the joint bracket After reinstalling the paper tray perform the side to side registration adjustment see Removal and Adjustment in the manual for the copier A D C ...

Page 265: ...per feed tray A 4 screws 2 Remove the feed roller B pick up roller C and reverse roller D 1 clip each NOTE After reinstalling the paper tray perform the side to side registration adjustment see Removal and Adjustment in the manual for the copier C B D A FT5535 4527 4522 8 14 FSM ...

Page 266: ... right rear cover see Exterior Cover Removal 3 Remove the drive unit A 2 screws 2 connectors 4 Remove the vertical transport unit B 2 screws 5 Remove the vertical transport guide C 4 screws 6 Remove the sponge D 7 Remove the relay sensors E 1 connector each B A C E D FSM 8 15 FT5535 4527 4522 ...

Page 267: ...SECTION 9 PS270 PAPER TRAY UNIT Machine Code A553 ...

Page 268: ...lb Copy Paper Capacity Approximately 250 sheets Paper Feed Speed 20 35 copies minute A4 81 2 X11 sideways Power Source DC 24V 5V and AC 120V 220 240V from the main machine Power Consumption Maximum 43 W Average 22 W Dimensions 620 mm 24 4 width X 632 mm 24 9 depth X 390 mm 15 4 height Weight Less than 30 kg 66 lb FSM 9 1 FT5535 4527 4522 ...

Page 269: ... 2 DRIVE LAYOUT 1 Paper Tray 1 2 Paper Feed Rollers 3 Relay Rollers 4 Lower Right Door 5 Paper Tray 2 1 Vertical Transport Roller Gears 2 Paper Feed Clutch 1 3 Paper Feed Clutch 2 4 Main Motor 5 Relay Clutch 1 2 3 4 5 1 2 4 3 1 5 FT5535 4527 4522 9 2 FSM ...

Page 270: ... set 2 S3 10 Relay 1 Detects when the leading edge of the paper leaves the paper tray to determine copier relay clutch timing and jam detection timing S4 11 Relay 2 S5 5 Paper end 1 Detects when the paper tray runs out of paper S6 6 Paper end 2 Switches SW1 12 Tray cover Detects whether the tray unit cover is open and cuts the 24 Vdc line if it is Clutches CL1 7 Paper feed 1 Starts to feed paper f...

Page 271: ... condition of the accessories in the box against the following list 1 Right Support Bracket 1 2 Left Support Bracket 1 3 Joint Bracket 1 4 Shoulder Screw 1 5 Screw M4 x 8 4 6 New Equipment Condition Report 1 7 Installation Procedure 1 FT5535 4527 4522 9 4 FSM ...

Page 272: ...ing retainers after installing the machine They will be reused if the machine is transported to another location in the future Proper reinstallation of the shipping retainers is required in order to avoid any transport damage 1 Remove the strips of tape 2 Remove the bottom plate stopper A Rev 7 95 A FSM 9 5 FT5535 4527 4522 ...

Page 273: ...ot do this the machine may fall forwards if all the paper trays are pulled open 9 Pull out the paper tray and load paper into it The paper size and direction for each tray should be designated by a customer NOTE The side and rear fences should be properly positioned 10 Turn on the main switch 11 Enter the proper paper size for each paper tray by following the instructions in the copier s manual 12...

Page 274: ...4 Install the clamper E and clamp the heater harnesses 5 Install the heater bracket F 2 screws 6 Connect the heater harnesses 7 Install the clamper G and clamp the heater harnesses NOTE After replacing the paper tray perform the side to side registration adjustment see the Removal and Adjustment section of the manual for the copier E A C B D G F FSM 9 7 FT5535 4527 4522 ...

Page 275: ...per feed tray 3 only On Off Free Run Mode 2 On On Free Run Mode 1 Do not touch dip switches 1 to 5 How to do a free run 1 Select either mode 1 or mode 2 with dip switches 6 and 7 2 Turn off the power disconnect the optical cable and turn on the power 3 Press SW101 on the PCB to start the free run 4 When you wish to stop the free run press SW102 on the PCB then reset the dip switches to their defau...

Page 276: ...4 2 TEST POINTS NUMBER FUNCTION TP101 5V TP102 24V TP103 GND TP104 TXD Transmit signal TP105 RXD Receive signal TP106 GND FSM 9 9 FT5535 4527 4522 ...

Page 277: ...nt lower cover 2 screws Right Front Cover C 1 Remove the front lower cover B 2 Remove the right front cover 2 screws Right Rear Cover D 1 Remove the rear cover A 2 Remove the right rear cover 2 screws Left Cover E 1 Remove the rear cover A 2 Remove the front lower cover B 3 Remove the left cover 4 screws A D C B E FT5535 4527 4522 9 10 FSM ...

Page 278: ... Remove the main motor bracket assembly B 2 screws 2 connectors 4 Remove the spring C 5 Remove the main motor D 4 screws 1 clip 1 gear NOTE When reinstalling the main motor assembly make sure that the relay clutch stopper groove engages with the stopper E on the main motor bracket A B E D C FSM 9 11 FT5535 4527 4522 ...

Page 279: ...ove the link bracket C 2 screws 3 Remove the bracket D 2 screws 4 Remove the second paper feed clutch E 1 connector Relay Clutch 1 Remove the rear cover see Exterior Cover Removal 2 Remove the link bracket C 2 screws 3 Remove the main motor bracket assemlby see Main Motor Replacement 4 Remove the relay clutch F 1 connector NOTE When you reinstall a clutch make sure that the clutch stopper groove e...

Page 280: ... down The two rollers without rubber should be at the center position of the shaft The normal roller position is a There are two extra roller positions for A size paper LT size paper b and B size paper c When paper jam and non feed errors occur change the feed roller position After reinstalling the paper tray perform the side to side registration adjustment see Removal and Adjustment in the manual...

Page 281: ...e Exterior Cover Removal 2 Remove the rear right cover see Exterior Cover Removal 3 Remove the vertical transport unit A 2 screws 4 Remove the vertical transport guide B 4 screws 5 Remove the relay sensors C 1 connector each A B C FT5535 4527 4522 9 14 FSM ...

Page 282: ...SECTION 10 ST26 20 BIN SORTER STAPLER Machine Code A554 ...

Page 283: ... g m2 14 21 lb Number of Bins 20 bins proof tray Bin Capacity Sort mode 30 sheets A4 81 2 x 11 15 sheets A3 11 x 17 Stack mode 15 sheets Proof tray 100 sheets 52 80 g m2 14 21 lb 50 sheets 81 128 g m2 22 34 lb 30 sheets 129 157 g m2 35 42 lb Stapler Capacity A4 81 2 x 11 or smaller 2 20 copies B4 81 2 x 14 or larger 2 10 copies Stapling Position a b a b 6 3 mm 0 24 0 12 Horizontal a b a 16 3 mm 0 ...

Page 284: ...0 staples cartridge Power Source DC 24V 5V form the copier Power Consumption 34 W Dimensions W x D x H 412 x 600 x 690 mm 16 2 x 23 6 x 27 1 Weight About 25 kg 55 1 lb Main Frame 22 kg 48 5 lb Mounting Frame 3 kg 6 6 lb FT5535 4527 4522 10 2 FSM ...

Page 285: ... Proof Tray Exit Rollers 3 Vertical Transport Rollers 4 Turn Gate 5 Bin Transport Belt 6 Bin Transport Roller 7 Bin Exit Roller 8 Stapler 9 Grip Assembly 10 Bin Support Block 11 Bins 12 Support Bin 13 Jogger Bar 1 2 3 4 5 6 7 8 9 10 11 12 13 FSM 10 3 FT5535 4527 4522 ...

Page 286: ...elt 15 Bin Transport Drive Gear 14 Bin Transport Belts 17 Vertical Transport Drive Pulley 11 Bin Lift Motor Pulley 8 Bin Lift Drive Belt 7 Bin Lift Gears 6 Bin Lift Gear Pulley 12 Rear Bin Lift Wire 9 Rear Bin Support Block 21 Bin Drive Shaft 20 Front Bin Lift Pulley 16 Front Bin Lift Wire 22 Front Bin Support Block 10 Jogger Motor Pulley 13 Lower Jogger Drive Belt 23 Jogger Bar 5 Jogger Drive Sha...

Page 287: ...ray or the bins 6 Sensors S1 Bin Lift Timing 1 Monitors the rotation of the bin lift motor by detecting the timing disk 24 S2 Bin Lift Timing 2 Controls the stop timing of the bin lift motor so that the bin lift timing sensor no 1 can detect the timing disk properly 25 S3 Jogger H P Detects whether the jogger bar is at the home position 19 S4 Paper Detects whether there are any copies under the ha...

Page 288: ...it position of the bins through the bin lift wire tension 21 SW3 Front Door Cuts the 24 Vdc line when the front door is open 14 SW4 Sorter Stapler Set Cuts the 24 Vdc line when the sorter stapler unit is open 7 SW5 Staple End Detects the staple end condition 10 SW6 Staple Guide Detects whether the staple guide plate is closed 9 SW7 Staple H P Detects whether the staple hammer is at the home positi...

Page 289: ...e box as listed below 1 Proof Tray 1 2 Staple Cartridge 1 3 Staple Position Decal 1 4 Stepped Screw 1 5 Philips Truss Head Screw M4 x 6 1 6 Philips Pan Head Screw M4 x 14 4 7 New Equipment Condition Report 17 machines only 1 8 Installation Procedure 1 FSM 10 7 FT5535 4527 4522 ...

Page 290: ...stapler Grasp the stay A when unpacking the sorter stapler Never hold the guide plate B when unpacking the sorter stapler If you hold the guide plate it might be damaged and this will cause paper jams Avoid catching the guide plate B on anything when installing the sorter stapler A B FT5535 4527 4522 10 8 FSM ...

Page 291: ... 3 A sorter adapter A568 is required to install this sorter stapler in the A157 A159 A160 A161 A162 copiers Before installing this sorter stapler please install the sorter adapter in the copier CAUTION Unplug the copier power cord before starting the following procedure 1 Remove the strips of tape and the shipping retainers A 2 Open the front door B and remove the strips of tape from the staple un...

Page 292: ...er left cover with nippers 4 Remove the rear cover B of the sorter stapler 5 Release the lock lever C of the sorter stapler and unhook the sorter stapler mounting frame D while releasing the stopper E as shown A C B E D FT5535 4527 4522 10 10 FSM ...

Page 293: ...F 1 snap ring before installing the sorter stapler This prevents the junction gate from damaging the guide plate of the sorter stapler mounting frame 9 Install the sorter stapler G on the sorter stapler mounting frame 2 hinge pins at the rear NOTE First lift the sorter stapler onto the support plate H opening the sorter stapler about 30 degrees Then insert the upper stud I into the upper hinge hol...

Page 294: ...ar of the copier 13 Connect the connectors A to the sockets on the rear of the copier 14 Remount the rear cover B 4 screws 15 Mount the proof tray C 1 screw as shown C A B Rev 10 11 95 Fiber Connector Plug P FT5535 4527 4522 10 12 FSM ...

Page 295: ... the stapler while holding the staple unit 18 Put the staple unit back in its original position close the sorter stapler front door and plug in the copier 19 Attach the staple position decal E to the ARDF as shown 20 Turn on the copier main switch and test the operation of the sorter stapler NOTE The stapler will not be stapling for the first 10 or so copies until the first staple comes to the pro...

Page 296: ...e roller drive motor turns on alternately at low and high speed The sorting operation is repeated from the 1st bin to the 20th bin Operated components Turn gate solenoid Bin lift motor Jogger motor for A4 sideways 2 Stapling is repeated from the 1st bin to the 20th bin If there are staples in the staple unit the stapling operation is skipped If there is paper in the bins the jogger motor does not ...

Page 297: ...TMENT 6 1 STAPLER REMOVAL 1 Open the front door A of the sorter stapler and swing the staple unit B up 2 Remove the staple unit cover C 1 screw 3 Remove the stapler D 1 screw and 1 connector A B C D FSM 10 15 FT5535 4527 4522 ...

Page 298: ... tray A 1 screw 2 Swing out the sorter stapler and disconnect the link lever B 1 stepped screw 3 Remove the front cover C remove 2 screws and loosen 2 screws 4 Remove the grip assembly D 2 screws and 1 connector A B C D FT5535 4527 4522 10 16 FSM ...

Page 299: ...MENT 1 Remove the proof tray A 1 screw 2 Remove the sorter stapler from the copier 3 Remove the jogger bar B as shown 4 Remove the upper securing screw of each bin link C 1 screw each A B C FSM 10 17 FT5535 4527 4522 ...

Page 300: ...2 Push the bin forward until the wheels C reach the bend in the track 3 Push the left side of the bin forward and pull that side up 4 As you pull the left side up the right wheel will leave its track 5 When the left wheel reaches the slot D pull the bin out A C D B FT5535 4527 4522 10 18 FSM ...

Page 301: ... Tilt the bin so the left side is higher then the right side 3 Pass the left wheel C through the slot D At the same time pass the right wheel E just below the stapler opening 4 Set the left wheel into the left track then push the right wheel into the right track A C D B E FSM 10 19 FT5535 4527 4522 ...

Page 302: ...g parts Proof Tray A 1 screw Front Cover B loosen 2 screws and remove 2 screws Rear Cover C 4 screws 3 Turn the bin lift drive belt so that the bin lift gear pulley component rotates counterclockwise Continue this until the rear bin lift wire becomes loose enough to remove the wire A C B FT5535 4527 4522 10 20 FSM ...

Page 303: ...tor 9P 5 Swing the bin shaft cover B as shown 2 screws and 1 connector 6 Remove the bin support block stopper C as shown 7 Remove the wire pulley D 1 E ring NOTE Be careful not to lose the pin E 8 Remove the bin lift wire F E F C D A B FSM 10 21 FT5535 4527 4522 ...

Page 304: ...rol board A 1 screw 13 connectors and 5 locking supports 11 Remove the bin lift shaft cover B 2 screws 12 Remove the timing sensor bracket C 1 screw 13 Remove the bin drive bracket D 2 screws with spring washer 1 connector and 3 wire saddles 14 Remove the bushing E B A C D E FT5535 4527 4522 10 22 FSM ...

Page 305: ...15 Remove the bin lift block stopper A as shown 16 Remove the wire pulley gear B 2 E rings NOTE Be careful not to lose the pin C 17 Remove the bin lift wire D B A D C FSM 10 23 FT5535 4527 4522 ...

Page 306: ...the bin support block stopper H on the bin support block 5 Run the wires over the pulleys Front wire I J K Rear wire L M N O and put the bead P in the slot in the bin lift shaft Q 6 Reassemble the sorter stapler NOTE When installing the bin drive bracket make sure that the bin lift wires are wound from the inner side to the outer side of the pulleys as shown 599mm 23 58 877 6 mm 34 55 A F P Rear F...

Page 307: ...d the upper cover 3 Remove the upper hinge A 2 screws and the sorter stapler set switch bracket B 1 screw 4 Remove the grounding screw C and disconnect the main harness D 5 connectors and 3 harness clamps 5 Remove the timing belt E from the pulley F 6 Remove the vertical transport unit G 8 screws B A C D F E G FSM 10 25 FT5535 4527 4522 ...

Page 308: ... tray the rear cover and the power cord bracket A 2 Disconnect the main control board connectors and fiber cable 3 Replace the main control board B and connect the connectors 4 Turn on the copier main switch 5 Adjust the bin sensor see the next page 6 Turn off the main switch B A FT5535 4527 4522 10 26 FSM ...

Page 309: ...r Adjustment 1 Turn on DIP SW100 5 A 2 If LED100 B is lit turn VR100 C counterclockwise until LED100 turns off 3 Turn VR100 clockwise until LED100 just turns on 4 Turn off DIP SW100 5 C B A FSM 10 27 FT5535 4527 4522 ...

Page 310: ...n adjustments as listed below Timing Belt A Roller Drive Motor Proof Tray Rear Cover Timing Belt B Grip Motor Proof Tray Front Cover 2 Adjust the timing belt tension as follows Timing Belt Bending Tension A 4 mm 0 16 150 50 g B 4 mm 0 16 200 50 g B A Bending a FT5535 4527 4522 10 28 FSM ...

Page 311: ...ys Low Jogger H P S3 4 0 V 1 0 V 170 2 Open stays High The Sorter Jam indicator starts blinking The Sorter Jam indicator starts blinking when copies are made in sort stack or staple mode After the sorter stapler or front door is opened closed SC code 722 will be displayed Shorted stays Low The jogger motor keeps rotating until the Sorter Jam indicator starts blinking Paper S4 4 0 V 1 0 V 140 5 Ope...

Page 312: ...icator starts blinking when copies are made in sort stack or staple mode After the sorter stapler or front door is opened closed SC code 723 will be displayed Shorted stays Low The grip motor keeps rotating until the Sorter Jam indicator starts blinking The Sorter Jam indicator starts blinking when copies are made in sort stack or staple mode After the sorter stapler or front door is opened closed...

Page 313: ...ator starts blinking when copies are made in normal mode Shorted stays Low The Sorter Jam indicator starts blinking Roller Drive Timing S11 4 0 V 1 0 V 150 11 Open stays High The Sorter Jam indicator starts blinking The Sorter Jam indicator starts blinking or SC code 720 is displayed when copies are made Shorted stays Low FSM 10 31 FT5535 4527 4522 ...

Page 314: ...rter Stapler Set SW4 100 3 Open C 5 is displayed even if the sorter stapler is closed Shorted C 5 is not displayed even if the sorter stapler is opened Staple End SW5 130 9 Open The Add Staples indicator does not light even though the staple cartridge is empty Shorted The Add Staples indicator lights even though the staple cartridge is not empty Staple Guide SW6 130 8 Open The Add Staples indicato...

Page 315: ...SECTION 11 ST10 10 BIN SORTER STAPLER Machine Code A555 ...

Page 316: ...Bin Capacity Sorting A4 81 2 x 11 or smaller 30 copies B4 81 2 x 14 or larger 25 copies Stacking A4 81 2 x 11 or smaller 25 copies B4 81 2 x 14 or larger 20 copies Stapler Capacity 2 20 copies Proof Tray Capacity 100 copies 52 80 g m2 14 21 lb 50 copies 81 128 g m2 22 34 lb 30 copies 129 157 g m2 35 42 lb Number of Bins 10 bins proof tray Stapling Position a 6 3 mm b 6 3 mm a b FSM 11 1 FT5535 452...

Page 317: ...dge Power Source DC 24V 5V from the copier Power Consumption Average less than 33 W Average for Sorting less than 25 W Average for Stapling less than 33 W Weight 12 4 kg 27 4 lb Dimensions W x D x H 381 x 548 x 443 mm 15 0 x 21 6 x 17 5 FT5535 4527 4522 11 2 FSM ...

Page 318: ...2 COMPONENT LAYOUT 2 1 MECHANICAL COMPONENT LAYOUT 7 1 2 3 4 5 6 1 Helical Wheels 2 Jogger Plate 3 Grip Assembly 4 Transport Rollers 5 Staple Unit 6 Bins 7 Proof Tray FSM 11 3 FT5535 4527 4522 ...

Page 319: ... 2 DRIVE LAYOUT 1 Jogger Drive Belt 2 Transport Roller 3 Helical Wheels 4 Transport Motor 5 Jogger Motor 6 Wheel Drive Belts 7 Bin Drive Motor 8 Jogger Plate 8 1 2 4 3 5 7 3 1 6 FT5535 4527 4522 11 4 FSM ...

Page 320: ... jams S3 15 Jogger H P Detects whether the jogger plate is in its home position S4 13 Timing Provides pulses to the sorter stapler main board S5 4 Stapler Paper Detects whether any copies are under the hammer S6 5 Grip H P Detects when the grip assembly cam gear has rotated once S7 11 Bin LED Detects whether there is paper in the bins light emitting element S8 10 Wheel Detects the bin position S9 ...

Page 321: ...essories in the box against the following list 1 Misfeed Removal Decal 1 2 Staple Position Decal 1 3 Chain 1 4 Cap Remover 1 5 Philips Pan Head Screw 4 x 8 1 6 Philips Pan Head Screw 4 x 14 4 7 New Equipment Condition Report 1 8 Installation Procedure 1 FT5535 4527 4522 11 6 FSM ...

Page 322: ...r CAUTION Unplug the copier power cord before starting the following procedure Do not lift the sorter stapler by holding the entrance guide A Otherwise the resulting damage may cause paper jams to occur at the entrance 1 Remove the strips of tape 2 Remove the cardboard pieces B and the foam blocks C Rev 7 95 A Incorrect Lifting Method B C C B C B FSM 11 7 FT5535 4527 4522 ...

Page 323: ...he openings D Then tighten four M4 x 14 screws For A157 A159 A160 A161 and A162 copiers First remove the screw E and fit the hooks B on the sorter stapler mounting frame C into the openings D Then tighten four M4 x 14 screws A D C D A153 A155 A156 copiers B B D D E A157 A159 A160 A161 A162 copiers B C FT5535 4527 4522 11 8 FSM ...

Page 324: ... NOTE This screw prevents the sorter stapler from falling down 7 Remove the Plug P from the rear of the copier 8 Connect the cable D and the optic cable E 9 Install the chain F as shown 10 Attach the misfeed removal decal G and the staple position decal H as shown above Rev 10 11 95 G D A H E C F B Incorrect Lifting Method Fiber Connector Plug P FSM 11 9 FT5535 4527 4522 ...

Page 325: ...Install the cartridge E in the stapler while holding the staple unit 13 Put the staple unit back to the original position close the sorter stapler front door and plug in the copier 14 Turn on the main switch and test the operation of the sorter stapler NOTE The stapler will not be stapling for the first 5 or so copies after installation until the first staple comes to the proper position from the ...

Page 326: ...itches 2 and 3 2 Set switch 1 to 1 The free run starts 3 To stop the free run set switch 1 to 0 4 Return switches 2 and 3 to their factory settings Free Run Mode Types Sorter Free Run Mode This mode advances and lowers the bins moves the jogger plate and changes the roller rotation speed from low to high for each bin Staple Free Run Mode This mode performs the jogger plate grip assembly and staple...

Page 327: ... Function TP100 24 V TP101 5 V TP102 GND 4 3 LED Number Function LED100 Bin jam sensor status 4 4 VARIABLE RESISTOR Number Function VR100 Bin jam sensor LED adjustment see Bin Jam Sensor Adjustment FT5535 4527 4522 11 12 FSM ...

Page 328: ...rews 2 Front Cover B 3 screws 3 Lower Cover C 1 screw 4 Top Cover D 2 screws 5 2 STAPLE UNIT REMOVAL 1 Remove the front cover see Exterior Cover Removal 2 Swing up the staple unit A 3 Remove the staple unit 1 connector 1 ground wire 1 clip D A C B A FSM 11 13 FT5535 4527 4522 ...

Page 329: ...e grip assembly A 4 screws 2 connectors 1 grounding wire 3 Remove the holder bracket B 1 screw 4 Remove the spring C and remove the slider D 5 Remove the grip arm unit E 1 screw 1 clip 6 Remove the grip arm plate F 2 screws 7 Replace the grip arms G A D C E F G B FT5535 4527 4522 11 14 FSM ...

Page 330: ... the jogger guide plate E 4 screws 6 Remove the wheel sensor bracket F 1 screw 7 Remove the bushings G 1 clip each 8 Remove the actuators H belts I and the gears J 1 clip on each side 9 Remove the helical wheels K 10 Remove the bins L NOTE When putting back the helical wheels at both the front and rear of the machine the parts labeled A should be pointing directly away from the machine F G K J I H...

Page 331: ...e lower plate B 3 screws 3 Remove the entrance guide C 4 screws 4 Remove the transport motor unit D 5 Remove the collar E 6 Remove the transport roller F 2 bushings 1 gear 7 Remove the transport motor cover G 8 Remove the transport motor H 3 screws A C B D E F G H FT5535 4527 4522 11 16 FSM ...

Page 332: ... main board perform the bin jam sensor adjustment as follows 1 Turn on the main switch 2 Remove any copies from the bins 3 Set switch 5 of DIP SW 100 on the sorter main board to the ON position 4 Turn VR 100 until LED 100 goes off FSM 11 17 FT5535 4527 4522 ...

Page 333: ...SECTION 12 CS220 20 BIN SORTER MINI α Machine Code A556 ...

Page 334: ...4 lb Non Sort Stack Mode 52 to 162 g m2 14 to 43 lb Bin Capacity Sort Stack Mode Bins 1 to 20 Non Sort Stack Mode Proof tray A4 81 2 x 11 or less 30 100 B4 81 2 x 14 15 10 100 A3 11 x 17 10 100 Power Source 5 volts and 24 volts from the copier Power Consumption 24 W Dimensions W x D x H 346 mm x 474 mm x 338 mm 13 6 x 18 7 x 13 3 Weight 12 5 kg 27 8 lb FSM 12 1 FT5535 4527 4522 ...

Page 335: ...MECHANICAL COMPONENT LAYOUT 1 Exit Rollers 2 Paper Guide 3 Roller Drive Belt 4 Wheel Drive Belt 5 Lift Bar 6 Securing Wire 7 Bins 8 Proof Tray 9 Transfer Wheel 8 7 9 1 6 2 4 5 3 FT5535 4527 4522 12 2 FSM ...

Page 336: ...PONENT LAYOUT 1 Paper Sensor S1 2 Wheel Drive Motor M1 3 Roller Drive Motor M2 4 Bin Home Position Sensor S2 5 Wheel Sensor S3 6 Sorter Main Board PCB1 7 Cover Safety Switch SW1 1 7 6 5 2 4 3 FSM 12 3 FT5535 4527 4522 ...

Page 337: ...d detection for the sorter S1 4 Bin Home Position Sensor Detects when all bins are in the down position home S2 5 Wheel Sensor Detects each half turn of the wheel 1 bin is changed for each half turn S3 Switch 7 Cover Safety Switch Detects when the sorter cover is opened SW1 Printed Circuit Board 6 Sorter Main Board Controls all sorter functions Communicates with the copier main board through the i...

Page 338: ...ORY CHECK Check the quantity and condition of the accessories in the box against the following list 1 Installation Procedure 1 2 New Equipment Condition Report 1 3 Entrance Guide Mylar 1 4 Knob Screw 2 FSM 12 5 FT5535 4527 4522 ...

Page 339: ...rder to avoid any transport damage 3 A sorter adapter A568 is required to install this sorter in the A157 A159 A160 A161 A162 copiers Before installing this sorter please install the sorter adapter in the copier CAUTION Unplug the copier power cord before starting the following procedure 1 Remove the strips of tape and the shipping retainer A 2 Attach the entrance guide mylar B to the entrance gui...

Page 340: ...ch the sorter to the copier with the two knob screws G NOTE Tighten these knob screws until they stop halfway Do not tighten them forcibly after they stop 7 Remount the sorter front cover B 2 screws and the rear cover C 4 screws and close the sorter top cover A 8 Remove the Plug P from the rear of the copier 9 Connect the connector H to the socket I on the rear cover of the copier Rev 10 11 95 B A...

Page 341: ...ntering SP mode 1 blinks in the 3rd digit of the copy counter the Auto Image Density indicator starts blinking and the reduce enlarge indicator turns off 3 The above procedure must be finished within 20 seconds 11 Press the following sequence of keys to change the SP6 101 value to 2 12 Turn the main switch off and on 13 Check the sorter s operation FT5535 4527 4522 12 8 FSM ...

Page 342: ... the copier 2 Remove the front cover 2 screws 3 Remove the rear cover 4 screws 4 Swing the guide plate A up then remove it carefully from the snaps on both sides by pulling it up 5 Remove the inner cover B 4 screws 6 Unhook the front C and rear D pressure springs D A B C A FSM 12 9 FT5535 4527 4522 ...

Page 343: ...ve motor and slip off the timing belt G 13 Slide off the wheel drive shaft H and remove the exit roller I and rubber belt J CAUTION Do not damage the paper sensor K when removing the exit roller 14 Replace the exit roller and rubber belt then reassemble the machine NOTE a When reinstalling the wheel sensor assembly be sure that the sensor does not touch the wheel b When remounting the wheel drive ...

Page 344: ... Remove the rear cover 4 screws 4 Swing up the guide plate A 5 Remove the inner cover B 4 screws 6 Replace the paper sensor C 1 screw and 1 connector and reassemble the machine CAUTION To avoid damaging the sensor do not over tighten the sensor mounting screw Rev 7 95 A C B FSM 12 11 FT5535 4527 4522 ...

Page 345: ...4 lb tension 1 Remove the front cover 2 Loosen the two mounting screws A of the wheel drive motor B 3 Press the timing belt C with a tension gauge D as shown in the diagram and adjust the tension by repositioning the wheel drive motor C A B D 200 g 0 44 lb 1 0 3 mm FT5535 4527 4522 12 12 FSM ...

Page 346: ...SECTION 13 CS130 10 BIN SORTER MICRO α Machine Code A557 ...

Page 347: ...4 lb Non Sort Stack Mode 52 to 162 g m2 14 to 43 lb Bin Capacity Sort Stack Mode All Bins Non Sort Stack Mode Top Bin A4 81 2 x 11 or less 20 100 B4 81 2 x 14 15 100 A3 11 x 17 10 100 Power Source 5 volts and 24 volts from the copier Power Consumption 15 W Dimensions W x D x H 402 mm x 455 mm x 217 mm 15 7 x 17 8 x 16 7 Weight 7 5 kg 16 5 lb FSM 13 1 FT5535 4527 4522 ...

Page 348: ...Exit Roller 4 Upper Paper Guide 5 Lower Paper Guide 6 Bin Guide Electrical Components 1 Sorter Main Board 5 Bin Drive Motor 2 Wheel Switch 6 Sorter Switch 3 Roller Drive Motor 7 Bin Home Position Switch 4 Paper Sensor 1 3 5 4 2 6 7 6 5 4 3 2 1 FT5535 4527 4522 13 2 FSM ...

Page 349: ... SW2 Sorter Switch This reed switch becomes activated when the sorter is in the proper position aligned next to the copier It also works as a jam reset switch for the sorter 6 SW3 Bin Home Position Switch Informs the CPU that all the bins are lowered 7 Sensors S1 Paper Sensor Serves as the misfeed sensor for the sorter and also sets exit roller and bin drive timing 4 Printed Circuit Boards PCB1 So...

Page 350: ...ondition of the accessories in the box against the following list 1 Magnet Catch 1 2 Sorter Holder Bracket 1 3 Tapping Screw M4 x 6 3 4 Tapping Screw M4 x 8 2 5 Snap Ring 1 6 Installation Procedure 1 7 New Equipment Condition Report 1 FT5535 4527 4522 13 4 FSM ...

Page 351: ...tainers is required in order to avoid any transport damage 3 Do not grasp the sorter by the top cover and stay as shown by A Hold both sides of the sorter as shown by B This is to prevent damage to the anti static brush C CAUTION Unplug the copier power cord before starting the following procedure 1 Remove the strips of tape D and styrofoam blocks E 2 Remove the copy tray F A C B D E D Rev 7 95 F ...

Page 352: ...ate A with nippers to remove the smaller part B 5 Remount the cover plate A 1 screw 6 Mount the sorter holder bracket C 3 tapping screws on the copier frame as shown 7 Mount the magnetic catch D on the exit cover 2 self tapping screws B A C D FT5535 4527 4522 13 6 FSM ...

Page 353: ...ys to enter SP mode NOTE 1 Hold the last key for more than 3 seconds 2 Upon entering SP mode 1 blinks in the 3rd digit of the copy counter the Auto Image Density indicator starts blinking and the reduce enlarge indicator turns off 3 The above procedure must be finished within 20 seconds 13 Press the following sequence of keys to change the SP6 101 value to 1 14 Turn the main switch off and on 15 C...

Page 354: ...e sure to prepare it for transportation as follows The sorter may be badly damaged if it is moved without proper preparation 1 If the bins are not at the home position turn on the main switch of the copier to move the bins to the home position 2 Secure the bins with strips of tape as shown in the illustration 3 Remove the sorter from the copier See the Installation Procedure FT5535 4527 4522 13 8 ...

Page 355: ...unding wire 6 Remove the entrance guide bracket G 2 screws 7 Lift the lower paper guide H out of position and turn it over to remove the roller drive belt I NOTE Be careful not to damage the bin home position switch actuator J when reassembling 8 Remove the transfer spacer K wheel L pin M and bushing N on both sides of the shaft 9 Slide the wheel shaft towards the front and replace the roller driv...

Page 356: ...rom the bin guides B 3 Apply Grease 501 to the grooves of the bin guides NOTE There are three types of bins types A B and C in the above diagram Therefore when installing the bins be sure that they are installed in the correct order A B C B C B C B C Grease 501 A B C Grease 501 B B A FT5535 4527 4522 13 10 FSM ...

Page 357: ...APPENDIX ...

Page 358: ...01 Drum Charge Voltage 1500V Manual ID Mode Table 9 Table 3 Table 4 SP2 001 Drum Charge Voltage 1500V VSP Pattern Detection Table 5 SP2 003 Drum Charge Voltage ID Sensor Pattern 1300V VL Pattern Detection Table 9 Table 3 Table 4 SP2 001 Drum Charge Voltage 1500V VR Pattern Detection Table 9 Table 3 Table 4 SP2 001 Drum Charge Voltage 1500V Non Image Area 0V DEVELOPMENT Develop ment Bias Voltage AD...

Page 359: ...fault 16 0V Table 5 T H Correction V SP Pattern for A153 A155 A156 copier Drum Charge Roller Temperature T Drum Rotation Time H 0 H 40 40 H 110 110 H 37 1 T 40 0 40 0 40 0 29 6 T 37 1 103 4 3 9xT 103 4 3 9xT 103 4 3 9xT 17 9 T 29 6 489 9 16 9xT 603 8 20 8xT 717 6 24 6xT 12 6 T 17 9 862 5 37 7xT 1164 2 52 1xT 1465 9 66 4xT T 12 6 387 0 508 0 629 0 T H Correction V SP Pattern for A157 A159 A160 copi...

Page 360: ...ge 0V 0V 40V 10V 80V 20V Table 11 VR Correction VR Level ID Correction Development Bias Correction Voltage 0V 40V 80V VRP VRG x 100 0 64 100 60 100 54 100 0V 1 47 63 42 59 36 53 40V 2 35 46 30 41 24 35 80V 3 26 34 21 29 16 23 120V 4 0 25 0 20 0 15 160V Table 12 TSC Detect Supply Mode TD Sensor Supply Mode VT VTREF 0 0196 Supply Ratio 7 15 30 60 0 0 0 0 0 1 3 7 15 30 60 4 5 15 30 45 60 6 7 30 45 60...

Page 361: ...APPENDIX AUTO PROCESS CONTROL TIMING CHART Every time after 1000 copies FT5535 4527 4522 A 4 FSM ...

Page 362: ...TECHNICAL SERVICE BULLETINS ...

Page 363: ...reas have been highlighted by an arrow 4 15 Updated Information Documentation error correction s 4 24 Updated Information Documentation error correction s 4 54 Additional Information PM Table Addition 4 56 Additional Information PM Table Addition 4 60 Additional Information PM Flowchart 5 27 Updated Information Drum Charge Roller Terminal Replacement Note This copy intended as master of original f...

Page 364: ...TED All FT4027 4527 5035 5535 copiers manufactured after Serial Number A3635020001 A3715020001 A3625020001 and A3695020001 respectively will have the new style Blade Cam installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in...

Page 365: ...er Terminal 0 1 39 41 30 NOTE The following changes apply to the FT5035 5535 only 2 Delete the AC Drive Board 115V A1535546 3 Change the description of the AC Drive Board 230V A1535545 to AC Drive Board 115V DELETE REFERENCE OLD PART NO DESCRIPTION QTY PAGE ITEM A1535546 AC Drive Board 115V 1 0 69 7 CHANGE DESCRIPTION REFERENCE PART NUMBER INCORRECT DESCRIPTION CORRECT DESCRIPTION PAGE ITEM A15356...

Page 366: ...he front door is opened or the paper tray is loaded and the copy job is resumed CAUSE E Version Software SOLUTION Install F Version or newer revision Software UNITS AFFECTED All FT4027 4527 5035 5535 copiers manufactured after Serial Number A3635020001 A3715020001 A3625020001 and A3695020001 respectively will have upgraded software installed during production ORDERING PROCEDURE To obtain the lates...

Page 367: ...Each serial number given will represent a request for one upgraded ROM Serial Number s 1 6 2 7 3 8 4 9 5 10 All serial number information will be verified before shipment is made NOTE Old ROM s must be returned within five 5 days to Ricoh Corporation 146 148 Sound Beach Avenue Old Greenwich CT 06870 PLEASE TYPE OR PRINT CLEARLY DEALER NAME ADDRESS CITY STATE ZIP CODE ATTENTION PHONE DEALER ACCOUNT...

Page 368: ... also used in error on page 44 Please replace page 44 of your FT5035 5535 Parts Catalog with the corrected page provided PAGES Please insert the following page into your FT5035 5535 Parts Catalog 44 Corrected Information Contains the correct illustration for page 44 Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY MECHANICAL PARTS PAPER PATH...

Page 369: ...was also used in error on page 44 Please replace page 44 of your FT5035 5535 Parts Catalog with the corrected page provided PAGES Please insert the following page into your FT5035 5535 Parts Catalog 44 Corrected Information Contains the correct illustration for page 44 Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY MECHANICAL PARTS PAPER P...

Page 370: ...A1551331 LCT Rear Right Cover for LCT Machine 1 9 9 27 DENOTES NEW ITEM 2 Correct the descriptions for the following parts REFERENCE PART NUMBER INCORRECT DESCRIPTION CORRECT DESCRIPTION PAGE ITEM FT5535 FT4527 A1571360 Operating Sheet Operating Sheet FT4027 9 5 A1581360 Operating Sheet Operating Sheet FT4527 9 5 A1531360 Operating Sheet Operating Sheet FT5035 9 5 A1541360 Operating Sheet Operatin...

Page 371: ...tively will have the new style Spring Plate installed during production UPDATE NO 3 LOWER FUSING GUIDE To reduce paper creasing at the Fusing Unit the height of the Lower Fusing Guide has been changed as shown REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM FT5535 FT4527 A1534196 A1534197 Lower Fusing Guide 1 1 1 49 47 1 UNITS AFFECTED All FT5535 5035 4527 4027 copiers manufactured...

Page 372: ...1873 Scanner Shoe Pin 0 4 31 29 17 DENOTES NEW ITEM UPDATE NO 5 SEAL 5 X 82 4 A cushion Seal has been added on the Cooling Fan Duct to prevent noise REFERENCE MODEL PART NUMBER DESCRIPTION QTY PAGE ITEM FT5535 5035 AA151177 Seal 5 x 82 x 4 0 2 70 21 FT4527 4027 AA151177 Seal 5 x 82 x 4 0 1 70 22 UNITS AFFECTED All FT5535 5035 4527 4027 copiers manufactured after Serial Number A3695030001 A36250300...

Page 373: ...tion increase is extremely high due to a continuous heavy copy run the Needle Pins may move over the lock ridge and into the narrower area resulting in a clutch lock SOLUTION The One Way Clutch has been changed to a different type to reduce the friction between the Feed Roller Shaft and Needle Pins The locations of the One Way Clutch are shown below NOTE The FT5035 uses 3 One Way Clutches and due ...

Page 374: ...at used in the other feed trays and is not subject to a clutch lock condition Therefore it is recommended that the FT5035 models without an LCT be modified as a first priority ORDERING PROCEDURE Ricoh Corporation will automatically ship 100 of the Clutch Rollers 20 of the Feed Roller Shafts and 10 of the Paper Feed Drive Rollers for all FT5035 5535 affected units shipped prior to 7 28 95 based on ...

Page 375: ...move the spring E and remove the timing belt F from the relay roller pulley G Disconnect the connector H from the lower paper feed unit 9 Remove the vertical transport guide plate I 1 screw 10 Pull out Paper Tray 2 and remove the lower paper feed unit J 2 screws 11 Remove the bracket K 2 screws 12 Remove the relay clutch L 1 connector 1 bushing 13 Remove the upper paper feed clutch M 1 E ring 1 co...

Page 376: ... clip 1 connector 2 Remove accessory connectors from rear of machine 3 Remove the rear cover 4 Remove the harness cover A 1 screw 5 Remove the LCT s rear cover B 2 screws 6 Remove the stopper bracket C 1 screw 7 Disconnect five connectors D and remove the harness bushing E 8 Remove the LCT Continued A D B C A E Q R P P The Feed Roller Shafts must also be replaced if the clutch P is locked Please r...

Page 377: ...er pulley G Disconnect the connector H from the lower paper feed unit 16 Remove the vertical transport guide plate I 1 screw 17 Remove the lower paper feed unit J 2 screws 18 Remove the bracket B 2 screws 19 Remove the relay clutch C 1 connector 1 bushing No need to carry out this procedure for the Units with a Duplex Tray 20 Remove the upper paper feed clutch D 1 E ring 1 connector 21 Remove the ...

Page 378: ...Tech Service Bulletin No 4027 4527 5035 5535 006 Page 6 of 8 Drive Belt Layout Continued Clutch and Gear Layout The FT5535 does not have this part The FT5535 does not have this part ...

Page 379: ...r 1 snap ring 2 Remove the retaining ring The ring is C shaped white plastic 3 Remove the Feed Roller Shaft If you are replacing the Paper Feed Drive Roller skip the procedure 4 and 5 4 Remove the other retaining ring from the Feed Roller Shaft and fix it to on the new Feed Roller Shaft 5 Install the new Feed Roller Shaft and reassemble the unit 6 Remove the upper Feed Stay 2 screws each side 7 Re...

Page 380: ...ment Procedure 1 Remove the Feed Roller 1 Snap ring 2 Remove the retaining ring The ring is C shaped white plastic 3 Remove the Feed Roller Shaft and remove the other retaining ring from the Feed Roller Shaft and fix it to the new Feed Roller Shaft 4 Reassemble the unit Front Rear Feed Roller Shaft ...

Page 381: ...se is extremely high due to a continuous heavy copy run the Needle Pins may move over the lock ridge and into the narrower area resulting in a clutch lock SOLUTION The One Way Clutch has been changed to a different type to reduce the friction between the Feed Roll er Shaft and Needle Pins The locations of the One Way Clutch are shown below NOTE The FT5035 uses 3 One Way Clutches and due to the LCT...

Page 382: ...ifferent type than that used in the other feed trays and is not subject to a clutch lock condition Therefore it is recommended that the FT5035 models without an LCT be modified as a first priority ORDERING PROCEDURE Ricoh Corporation will automatically ship 100 of the Clutch Rollers 20 of the Feed Roller Shafts and 10 of the Paper Feed Drive Rollers for all FT5035 5535 affected units shipped prior...

Page 383: ...move the spring E and remove the timing belt F from the relay roller pulley G Disconnect the connector H from the lower paper feed unit 9 Remove the vertical transport guide plate I 1 screw 10 Pull out Paper Tray 2 and remove the lower paper feed unit J 2 screws 11 Remove the bracket K 2 screws 12 Remove the relay clutch L 1 connector 1 bushing 13 Remove the upper paper feed clutch M 1 E ring 1 co...

Page 384: ... clip 1 connector 2 Remove accessory connectors from rear of machine 3 Remove the rear cover 4 Remove the harness cover A 1 screw 5 Remove the LCT s rear cover B 2 screws 6 Remove the stopper bracket C 1 screw 7 Disconnect five connectors D and remove the harness bushing E 8 Remove the LCT Continued A D B C A E Q R P P The Feed Roller Shafts must also be replaced if the clutch P is locked Please r...

Page 385: ...er pulley G Disconnect the connector H from the lower paper feed unit 16 Remove the vertical transport guide plate I 1 screw 17 Remove the lower paper feed unit J 2 screws 18 Remove the bracket B 2 screws 19 Remove the relay clutch C 1 connector 1 bushing No need to carry out this procedure for the Units with a Duplex Tray 20 Remove the upper paper feed clutch D 1 E ring 1 connector 21 Remove the ...

Page 386: ...Tech Service Bulletin No 4027 4527 5035 5535 006 Page 6 of 8 Drive Belt Layout Continued Clutch and Gear Layout The FT5535 does not have this part The FT5535 does not have this part ...

Page 387: ...er 1 snap ring 2 Remove the retaining ring The ring is C shaped white plastic 3 Remove the Feed Roller Shaft If you are replacing the Paper Feed Drive Roller skip the procedure4 and 5 4 Remove the other retaining ring from the Feed Roller Shaft and fix it to on the new Feed Roller Shaft 5 Install the new Feed Roller Shaft and reassemble the unit 6 Remove the upper Feed Stay 2 screws each side 7 Re...

Page 388: ...ement Procedure 1 Remove the Feed Roller 1 Snap ring 2 Remove the retaining ring The ring isC shaped white plastic 3 Remove the Feed Roller Shaft and remove the other retaining ring from the Feed Roller Shaft and fix it to the new Feed Roller Shaft 4 Reassemble the unit Front Rear Feed Roller Shaft ...

Page 389: ... A0531957 Flex Hinge Platen Cover 0 2 1 11 13 DENOTES NEW ITEM UNITS AFFECTED Not available at time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT...

Page 390: ...E ITEM FT5535 FT4527 AA140557 AA140599 Scanner Drive Shaft 1 1 3 S 35 33 4 AB033063 AB033069 Timing Pulley 22Z 24Z 2 2 3 S 35 33 3 05730040E 05730100E Hexagon Headless Set Screw M3 X 10 2 2 3 S 35 33 101 UNITS AFFECTED All FT5535 5035 copiers manufactured after Serial Number A3695050001 and A3625050001 respectively and all FT4527 4027 copiers manufactured after Serial Number A371506XXXX and A36350...

Page 391: ...3915 Gear 26Z 0 1 39 23 37 23 37 23 DENOTES NEW ITEM UPDATE NO 4 CHARGE ROLLER TERMINAL ASSEMBLY The Charge Roller Terminal Assembly shown below has been made available as a service part REFERENCE NEW PART NUMBER DESCRIPTION QUANTITY MODEL FT5535 5035 FT4027 4527 FT4522 4022 PAGE ITEM PAGE ITEM PAGE ITEM A1532119 Charge Roller Terminal Assembly 0 1 31 41 31 39 31 39 DENOTES NEW ITEM Continued Roll...

Page 392: ... Push Switch 71 5 UPDATE NO 6 FUSING UNIT The following Fusing Unit parts were omitted from the Parts Catalog Please add this information to your Parts Catalog REFERENCE PART NUMBER DESCRIPTION MODEL FT5535 5035 FT4027 4527 FT4522 4022 PAGE ITEM PAGE ITEM PAGE ITEM A1534005 Fusing Unit 115V FT5535 5035 47 A1574005 Fusing Unit 115V FT4527 4027 45 A1614002 Fusing Unit 115V FT4522 4022 45 A1344250 Fu...

Page 393: ...ON MODEL FT5535 5035 FT4027 4527 FT4522 4022 PAGE ITEM PAGE ITEM PAGE ITEM 11025981 Fiber Connector Plug 71 22 71 23 71 23 DENOTES NEW ITEM FIELD SERVICE MANUAL INSERT The Field Service Manual page s listed below must be replaced with the page s supplied Each bulletin package contains 2 sets of replacement pages PAGES The revised areas have been highlighted by an arrow 7 6 Updated Information 8 7 ...

Page 394: ...elow PRODUCTION COUNTERMEASURE The Wiper Arm Spring has been modified and is now available as a service part NOTE Add the Wiper Arm Spring to your Parts Catalog REFERENCE NEW PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM AA066246 Spring 0 1 39 24 37 24 CUSTOMER SERVICE GROUP F S M COPY QUALITY MECHANICAL PARTS PAPER PATH ELECTRICAL OTHER Note This copy int...

Page 395: ...fusing lamp switches OFF until the fuser reaches the temperatur e selected with SP1 105 002 The longer the the fusing lamp has been OFF the longer the recovery t ime see diagram below Continued CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PARTS Power Consumption in Watts W Cop...

Page 396: ...n switch with an incorporated coil is used When the CPU drops CN143 1 from 24V to 0 the main switch contacts are opened The wiring diagram and connector layout are shown below NOTE For part numbers refer to Technical Service Bulletin No 4027 4527 5035 5535 4022 4522 011 ANTI CONDENSATION HEATER CONNECTORS To meet very strict power consumption specifications in Auto OFF mode the anti condensation h...

Page 397: ...010 Page 3 of 6 Connector Layout Main SW Terminal No Wire Color Connector Color White Yellow Blue Blue Black Yellow Red Blue Yellow White Orange White Relay Terminal l No Wire Color Connector Color White Yellow Orange White Black Blue White Green Continued ...

Page 398: ...for all FT5035 5535 FT4027 4527 and FT4022 4522 copiers Continued Mode No Function Settings SP5 911 Copy mode selected when machine is turned on FT5535 FT4527 FT4522 copiers 1 Duplex Copy Mode Default 2 Single Side Copy Mode SP5 102 Auto energy saver time can be selected 1 120 minutes 1 minute per step Default 15 minutes SP5 305 Auto off time can be selected 1 120 minutes 1 minute per step Default...

Page 399: ...Tech Service Bulletin No 4027 4527 5035 5535 4022 4522 010 Page 5 of 6 Continued ...

Page 400: ...Tech Service Bulletin No 4027 4527 5035 5535 4022 4522 010 Page 6 of 6 ...

Page 401: ... Switch Bracket 1 1 3 67 12 67 12 67 12 A1535562 Main Sw Relay Harness 0 1 67 13 67 13 67 13 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machin...

Page 402: ...06 IC 4M x 16 120NS ROM 1 1 3 69 4 T 2 69 4 69 4 T 1 A1535545 A1535550 AC Drive Board 120V 1 1 1 69 7 69 11 69 11 T 1 A1545309 A1565509 Duplex Rear Harness FT5535 1 1 1 69 17 T 1 A1585309 A1565509 Duplex Rear Harness FT4527 4522 1 1 1 69 17 69 17 NA TP A1535311 A1535511 Rear Lower Harness FT5035 1 1 1 69 17 T 1 A1575311 A1575511 Rear Lower Harness 2 Tray FT4022 4027 1 1 1 69 17 69 17 NA TP A154531...

Page 403: ...3508XXXX FT4022 A364508XXXX FT5535 A3695070001 FT4527 A371508XXXX FT4522 A372508XXXX T 2 FT5035 A3625080001 FT4027 A363509XXXX FT4022 A364509XXXX FT5535 A3695080001 FT4527 A371509XXXX FT4522 A372509XXXX T 3 FT5035 A362509XXXX FT4027 NA FT4022 NA FT5535 NA FT4527 NA FT4522 NA UPDATE NO 2 PARTS CATALOG CORRECTION Please correct your Parts Catalog as follows REFERENCE PART NUMBER INCORRECT DESCRIPTIO...

Page 404: ...Main Switch Bracket 1 1 3 67 12 67 12 67 12 A1535562 Main Sw Relay Harness 0 1 67 13 67 13 67 13 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW ma...

Page 405: ...1535106 IC 4M x 16 120NS ROM 1 1 3 69 4 T 2 69 4 69 4 T 1 A1535545 A1535550 AC Drive Board 120V 1 1 1 69 7 69 11 69 11 T 2 A1545309 A1565509 Duplex Rear Harness FT5535 1 1 1 69 17 T 1 A1585309 A1565509 Duplex Rear Harness FT4527 4522 1 1 1 69 17 69 17 NA TP A1535311 A1535511 Rear Lower Harness FT5035 1 1 1 69 17 T 1 A1575311 A1575511 Rear Lower Harness 2 Tray FT4022 4027 1 1 1 69 17 69 17 NA TP A1...

Page 406: ... A363508XXXX FT4022 A364508XXXX FT5535 A3695070001 FT4527 A371508XXXX FT4522 A372508XXXX T 2 FT5035 A3625080001 FT4027 A363509XXXX FT4022 A364509XXXX FT5535 A3695080001 FT4527 A371509XXXX FT4522 A372509XXXX T 3 FT5035 A362509XXXX FT4027 NA FT4022 NA FT5535 NA FT4527 NA FT4522 NA UPDATE NO 2 PARTS CATALOG CORRECTION Please correct your Parts Catalog as follows REFERENCE PART NUMBER INCORRECT DESCRI...

Page 407: ... Catalog documentation UPDATE NO 1 FUSING UNIT Part Numbers have been assigned for the following Fusing Unit components Continued CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PARTS Fusing Unit Assembly Fusing Exit Unit shown in the expolded view above Fusing Slide Rail Fusing ...

Page 408: ...4250 Fusing Exit Frame 0 1 49 19 47 19 47 19 A1344280 Fusing Exit Guide Lower 0 1 49 20 47 20 47 20 AF020326 Exit Roller Ass y 0 1 49 21 47 21 47 21 AF040548 Exit Drive Roller 0 2 49 22 47 22 47 22 A1344272 Roller Holder 0 2 49 23 47 23 47 23 08053480 Bushing 6mm 0 1 49 107 47 107 47 107 UPDATE NO 2 PART CATALOG ADDITION Add the following part numbers to your Parts Catalog REFERENCE PART NUMBER DE...

Page 409: ...e following Serial Numbers FT5035 5535 A3625040001 A3695040001 FT4027 4527 A363507XXXX A371507XXXX INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW ...

Page 410: ...531750 A1531749 Scale Bracket 1 1 3 S 9 30 9 31 DENOTES NEW ITEM UNITS AFFECTED The Left Original Scale and Scale Bracket were cut into production with the following Serial Numbers FT5035 5535 A362508XXXX A3695070016 FT4027 4527 A363508XXXX A371508XXXX FT4022 4522 A364508XXXX A372508XXXX INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be us...

Page 411: ...lightly warped when installed on the main frame UNITS AFFECTED Not available at time of publication UPDATE NO 3 VERTICAL TRANSPORT GUIDE SPACER To prevent the sensor on the vertical transport guide from chattering a spacer has been added between the guide and the LCT REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1556112 Spacer LCT 0 1 17 38 17 3...

Page 412: ...22 A372510XXXX NOTE Part number information for the FT4022 was not available at time of publication UPDATE NO 5 LOWER INNER COVER To prevent possible damage to the fusing idle gear by colliding against the lower inner cover when the fusing unit is slid back into the machine with the exit guide open the lower inner cover has been enlarged to reduce the gap between the gear and the cover as shown to...

Page 413: ... 1 49 14 47 14 UNITS AFFECTED The Front and Rear Fusing Guides were cut into production with the following Serial Numbers FT5035 5535 A362509XXXX A3695080001 FT4027 4527 A3635900175 A3715890431 FT4022 4522 A3645890461 A3725890263 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW mac...

Page 414: ...opiers manufactured after Serial Number A362512XXXX and A3695110001 respectively will have the new style Thermistors installed during production UPDATE NO 3 CUSHION A cushion has been added as indicated to prevent originals on the LCT from dropping into the feed station NOTE Align the edge of the cushion at the point where the stay is bent at a slight angle REFERENCE PART NUMBER DESCRIPTION QUANTI...

Page 415: ...or the fusing unit and the fusing exit frame have been changed and the part number for the stripper bracket ass y has been registered to facilitate servicing in the field REFERENCE OLD PART NUMBER NEW PART NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1344112 A1534112 Stripper Bracket 1 1 3 S 47 19 45 19 A1344250 A1534250 Fusing Exit Frame 1 1 2 49 19 47 1...

Page 416: ...ulley has been changed to a dual flange type REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA043375 AA043411 Timing Belt S2M300 1 1 1 61 2 AB030475 AB030536 Pulley 18Z S2M 2 2 1 59 14 All FT5035 5535 copiers manufactured after Serial Number A362511XXXX and A3695100001 will have the new style Timing Belt and Pulley installed during production UPDATE NO 6 SPRING The Pressure Spring...

Page 417: ...5035 5535 A362510XXXX A3695090001 FT4027 4527 A3635900175 A3715900676 FT4022 4522 A3645900101 A3725910041 UPDATE NO 7 FUSING LOCK LEVER To prevent the Front Cover from closing when the Fusing Unit is not set in the machine completely the Fusing Lock Lever has been changed REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A1344352 A153 4352 Fusing Lock Lever 1 1 1 75 1 UNITS AFFECTED ...

Page 418: ...o all FT5035 5535 4027 4527 4022 74522 Parts Catalogs Each bulletin package contains 1 set of insert pages PAGES The revised areas have been highlighted by an arrow 69A 69B Additional Information FT5035 5535 Main Board Components 69A 69B Additional Information FT4027 4527 Main Board Components 69A 69B Additional Information FT4022 4522 Main Board Components ...

Page 419: ...nt 0 1 49 14 47 14 UNITS AFFECTED The Front and Rear Fusing Guides were cut into production with the following Serial Numbers FT5035 5535 A362509XXXX A3695080001 FT4027 4527 A3635900175 A3715890431 FT4022 4522 A3645890461 A3725890263 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW...

Page 420: ...2 4027 4527 5035 5535 copiers manufactured after Serial Number A3646820006 A3726810040 A3636820001 A3716811004 A362512XXXX and A3695110001 respectively will have the new style Thermistors installed during production UPDATE NO 3 CUSHION A cushion has been added as indicated to prevent originals on the LCT from dropping into the feed station NOTE Align the edge of the cushion at the point where the ...

Page 421: ...rs for the fusing unit and the fusing exit frame have been changed and the part number for the stripper bracket ass y has been registered to facilitate servicing in the field REFERENCE OLD PART NUMBER NEW PART NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1344112 A1534112 Stripper Bracket 1 1 3 S 47 19 45 19 A1344250 A1534250 Fusing Exit Frame 1 1 2 49 19 ...

Page 422: ...he pulley has been changed to a dual flange type REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM AA043375 AA043411 Timing Belt S2M300 1 1 1 61 2 AB030475 AB030536 Pulley 18Z S2M 2 2 1 59 14 All FT5035 5535 copiers manufactured after Serial Number A362511XXXX and A3695100001 will have the new style Timing Belt and Pulley installed during production UPDATE NO 6 SPRING The Pressure Sp...

Page 423: ...15900676 FT4022 4522 A3645900101 A3725910041 UPDATE NO 7 FUSING LOCK LEVER To prevent the Front Cover from closing when the Fusing Unit is not set in the machine completely the Fusing Lock Lever has been changed REFERENCE OLD PART NUMBER NEW PART NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1344352 A153 4352 Fusing Lock Lever 1 1 1 75 1 75 8 UNITS AFFECTE...

Page 424: ... into all FT5035 5535 4027 4527 4022 74522 Parts Catalogs Each bulletin package contains 1 set of insert pages PAGES The revised areas have been highlighted by an arrow 69A 69B Additional Information FT5035 5535 Main Board Components 69A 69B Additional Information FT4027 4527 Main Board Components 69A 69B Additional Information FT4022 4522 Main Board Components ...

Page 425: ...orporated into all existing Parts Catalog documentation UPDATE NO 1 DUPLEX TRAY ASSEMBLY A part number has been assigned for the Duplex Tray Assembly REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 FT4527 4522 PAGE ITEM PAGE ITEM A1564605 Duplex Tray Ass y 0 1 51 A1584600 Duplex Tray Ass y 0 1 49 Continued CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as ...

Page 426: ...T NUMBER CORRECT PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1556111 A1556110 Front Side Plate 1 1 19 29 19 29 2 The part number for the Scanner Home Sensor Bracket is missing from the Parts Catalog REFERENCE PART NUMBER DESCRIPTION MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1531981 Scanner Home Sensor Bracket 33 28 31 28 Continued Sca...

Page 427: ...MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1533227 Toner End Sensor Cover 0 1 39 25 37 25 04523010B Tapping Bind Screw M3 x 10 0 1 39 107 37 107 DENOTES NEW ITEM UNITS AFFECTED The Toner End Sensor Cover was cut into production with the following Serial Numbers FT5035 5535 A3626010001 A3696010001 FT4027 4527 A3635920351 A3715911339 FT4022 4522 A3645910358 A3725910041 Continued To...

Page 428: ...een assigned for the Duplex Guide Mylar REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 FT4527 4522 PAGE ITEM PAGE ITEM A1344670 Duplex Guide Mylar 0 1 55 25 53 25 DENOTES NEW ITEM Duplex Guide Mylar Mylar position The distance between the edge of the mylar and the center of the feed roller shaft is 16 2 0 3 mm Feed Roller Shaft 16 2 0 3mm Mylar ...

Page 429: ...ODEL OLD MAIN BOARD NEW MAIN BOARD OLD ROM NEW ROM FT5035 5535 A1535101 A1535181 A1535104 H A1535106 A FT4027 4527 4022 4522 A1575101 A1575181 NOTE 1 When replacing the Main Board install the old RAM Board on the new Main Board 2 If the data in the old RAM Board is damaged leave the new RAM Board on the new Main Board and perform the Reset All Memory procedure found on pages 4 12 and 4 13 of the F...

Page 430: ...TS AFFECTED All FT5035 5535 copiers manufactured after Serial Number A3626010001 and A3695090001 respectively will have the new style parts listed above installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW mach...

Page 431: ...IPTION QTY INT PAGE ITEM A1533867 A1533865 Belt Drive Roller 1 1 1 45 14 UNITS AFFECTED All FT5035 5535 copiers manufactured after Serial Number A3626010001 and A3696010001 respectively will have the new style Belt Drive Roller installed during production UPDATE NO 3 PART NUMBER ASSIGNMENTS Part numbers have been assigned for the following parts Continued Old New Tapering Part This part has been r...

Page 432: ...5 5535 4022 4522 018 Page 3 of 5 Continued Front Scanner Stay Rear Scanner Stay Main Switch Bracket Interlock Switch Bracket Left Grip Arm Right Bracket Grip Plate Left bracket Grip Plate Left Grip Arm Toner Supply Stay Interlock Switch Arm ...

Page 433: ...Tech Service Bulletin No 4027 4527 5035 5535 4022 4522 018 Page 4 of 5 Continued Tray Unit Bracket ARDF Bracket Second Mylar ...

Page 434: ...canner Stay 0 1 31 18 29 17 A1531772 Front Scanner Stay 0 1 31 19 29 18 A1535809 Interlock Switch Arm 0 1 67 14 67 13 A1535808 Interlock Switch Bracket 0 1 67 15 67 14 A1341071 Left Grip Arm 0 4 67 16 67 15 A1341072 Right Bracket Grip Plate 0 2 67 17 67 16 A1341073 Left Bracket Grip Plate 0 2 67 18 67 17 A1533270 Toner Supply Stay 0 1 67 19 67 18 A1535806 Tray Unit Bracket 0 1 69 19 69 20 A1535807...

Page 435: ...ow REFERENCE OLD PART NUMBER NEW PART NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM AA080193 AA080219 Rear Roller Bushing 1 1 3 S 41 5 39 5 AA145795 AA145808 Rear Support Shaft 1 1 3 S 41 12 39 12 UNITS AFFECTED All FT4022 4522 4027 4527 5035 5535 copiers manufactured after Serial Number A3646810031 A3726810040 A3636810278 A3716810686 A3626010001 and A36950...

Page 436: ... PAGE ITEM PAGE ITEM A1533867 A1533865 Belt Drive Roller 1 1 1 45 14 43 13 UNITS AFFECTED All FT4022 4522 4027 4527 5035 5535 copiers manufactured after Serial Number A3646830512 A3726830001 A3636830206 A3716830741 A3626010001 and A3696010001 respectively will have the new style Belt Drive Roller installed during production UPDATE NO 3 PART NUMBER ASSIGNMENTS Part numbers have been assigned for th...

Page 437: ...5 5535 4022 4522 018 Page 3 of 5 Continued Front Scanner Stay Rear Scanner Stay Main Switch Bracket Interlock Switch Bracket Left Grip Arm Right Bracket Grip Plate Left bracket Grip Plate Left Grip Arm Toner Supply Stay Interlock Switch Arm ...

Page 438: ...Tech Service Bulletin No 4027 4527 5035 5535 4022 4522 018 Page 4 of 5 Continued Tray Unit Bracket ARDF Bracket Second Mylar ...

Page 439: ...canner Stay 0 1 31 18 29 17 A1531772 Front Scanner Stay 0 1 31 19 29 18 A1535809 Interlock Switch Arm 0 1 67 14 67 14 A1535808 Interlock Switch Bracket 0 1 67 15 67 15 A1341071 Left Grip Arm 0 4 67 16 67 16 A1341072 Right Bracket Grip Plate 0 2 67 17 67 17 A1341073 Left Bracket Grip Plate 0 2 67 18 67 18 A1533270 Toner Supply Stay 0 1 67 19 67 19 A1535806 Tray Unit Bracket 0 1 69 19 69 20 A1535807...

Page 440: ...535 Parts Catalog documentation REFERENCE PART NUMBER DESCRIPTION QTY PAGE ITEM AH01 0007 Rubber Foot 0 4 75 15 AW01 0065 Auto Response Sensor 0 1 9 33 UPDATE NO 2 Please correct page 8 of the FT4022 4522 Parts Catalog as follows CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy intended as master of original for reproduction of additional bulletins F S M COPY QUALITY PA...

Page 441: ... turn ON or turns ON intermittently CAUSE 1 The LEDs on the Quenching Lamp are broken or OPEN 2 Poor solder joints attaching the Quenching Lamp wiring harness SOLUTION 1 Replace the Quenching Lamp A1532090 2 Re solder the wires to the Quenching Lamp UNITS AFFECTED Any FT5535 Series copier exhibiting the above symptoms CUSTOMER SERVICE GROUP MECHANICAL PAPER PATH ELECTRICAL OTHER Note This copy int...

Page 442: ...using temperature Is it set too high The maximum temperature is 190 C Is the thermistor coming in contact with the roller Confirm that the thermistor comes in firm cont act with the roller Check for deformation of the thermistor unit Is the thickness of the paper within specifications Standard 14 42lbs Install the new style Fusing Thermistor refer to TSB FT4027 4527 5035 5535 4022 4522 015 Update ...

Page 443: ...n this case the nip area sho uld be increased and the temperature setting should be raised Electrostatic Offset When using OHPs or laminated paper offsets appear scattered around the characters Action Are the fusing roller and pressure roller properly grounded Make sure that the static brush on the back of the rollers is touching both the hot and pressure rollers see illustration below What is the...

Page 444: ...hat this roller is th e cause of the problem are very slight Horizontal Black Line A narrow horizontal black line not on the original appears on the copy 125mm from the front edge o r continues at a 125mm pitch This only occurs when there are no blank areas on the leading or traili ng edges blank edges are 0 mm Action Ensure that blank areas are created on both the leading and trailing edges 0 mm ...

Page 445: ...Back of the original was copied 2 The offset pitch is 188 5mm Cause A scratched drum Replace the drum 3 Irregular Occurrences Fused Image Cause Defective drum cleaning Confirm that the parts around the drum are functioning properly cleaning blade etc 4 Images on the surface unrelated to the original lines appear parallel to the paper feed direction Cause Defective drum cleaning scratched drum and ...

Page 446: ...oller The degree of toner accumulation on the charge roller is directly related to the cleaning ability of the cleaning blade As a result of this accumulation the ability to charge the drum surface decreases which leads to the white lighter lines bands on the copy SOLUTION In addition to cleaning the charge roller please check the cleaning blade Even if no defective or deteriorated areas can be fo...

Page 447: ...1 and A3716850136 respectively will have the new style Timing Pulley and Spacer installed during production Note FT5035 5535 information was not available at the time of publication INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW mac...

Page 448: ...UPDATE NO 2 STRIPPER STOPPER The Stripper Stopper is available as a service part REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1534114 Stripper Stopper 8 47 28 45 28 DENOTES NEW ITEM Stripper Stopper Hot Roller Stripper ...

Page 449: ...151 A3636850001 and A3716850136 respectively will have the new style Timing Pulley and Spacer installed during production Note The FT5035 5535 copiers do not utilize this item INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines ...

Page 450: ...UPDATE NO 2 STRIPPER STOPPER The Stripper Stopper is available as a service part REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1534114 Stripper Stopper 8 47 28 45 28 DENOTES NEW ITEM Stripper Stopper Hot Roller Stripper ...

Page 451: ...PAGE ITEM A153 2253 A153 2255 Drum Unit 1 1 41 43 39 41 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD m...

Page 452: ...tively will have the new style Magnetic Clutch installed during production The FT5035 5535 copiers do not utilize this item UPDATE NO 3 REVERSE GUIDE PLATE To prevent mis feeding two Mylars have been added on the Reverse Guide Plate REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A1342840 A1342839 Reverse Guide Plate 1 1 1 23 25 1 UNITS AFFECTED All FT5035 5535 copiers manufactured...

Page 453: ... TABLE A metal bracket has been added to the hinge on the By Pass Feed Table to strengthen it against breakage REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A1342691 A1342692 By Pass Feed Table Ass y 1 1 1 13 13 A1342696 A1342697 By Pass Feed Table 1 1 1 13 21 UNITS AFFECTED All FT5035 5535 copiers manufactured after Serial Number A3626050001 and A3696050001 respectively will hav...

Page 454: ...tio of this problem is extremely low SYMPTOM 2 SC525 CONTINUOUS POWER TO JOGGER MOTOR The Jogger Motor is continuously supplied with power but does not rotate which leads to overheating and possible deformation of the mold around the Duplex Unit SC525 may be indicated in Duplex Mode because the Jogger Motor is not rotating NOTE We would like to emphasize that the occurrence ratio of this problem i...

Page 455: ...e deformed due to excessive heat generated by the Jogger Motor If this has occurred replace the entire Duplex Tray when installing the new ROM NOTE Contact your Regional TSM for warranty information regarding the replacement of the Duplex Unit if this problem occurs SOLUTION 3 The software will be modified so that the Transfer Bias shuts OFF when the Main Motor stops REFERENCE OLD PART NUMBER NEW ...

Page 456: ...5 All serial number information will be verified before shipment is made NOTE Old ROM s must be returned within five 5 days to Ricoh Corporation 2001 West Main Street Suite 255 Stamford CT 06902 UNITS AFFECTED All FT4027 4527 5035 5535 4022 4522 copiers manufactured after Serial Number A3636870152 A3716810214 A3626060001 A3696060001 A3646870176 A3726870076 respectively will have the updated softwa...

Page 457: ...A3646870176 and A3726870076 respectively will have the new style Hot Roller Strippers installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT ...

Page 458: ... UNITS AFFECTED All FT5035 5535 4027 4527 4022 4522 copiers manufactured after Serial Number A3626080001 A3696080001 A3636870121 A3716860084 A3646860046 and A3726860134 respectively will have the new style Entrance Guide Plate installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can b...

Page 459: ...umber has been assigned for the IC 2 on the Main Board REFERENCE PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1535117 MPU HD6435708A05F 1 1 69 B 127 69 B 127 DENOTES NEW ITEM NOTE Add the Symbol No IC 2 and Index No 127 to the IC Chart on page 69 A ...

Page 460: ... created by the Developer if foreign material gets caught between the Drum and the outside Entrance Seal A Figure 2 3 Glue is transferred to the OPC surface from adhesive backed throughput materials labels etc or from the backside of the Development Entrance Seal Occasionally the glue is then transferred to the Entrance Seal when the drum turns in reverse This results in in the deformation of the ...

Page 461: ...place the seals AA142333 AA152334 with new ones Be sure to first clean the areas where the seals will be attached Continued A A Align the edge of the seal with the edge of the bracket 0 1mm 2 AA150382 20 AA150231 2 AA150382 AA152333 AA152334 Align the edge of the seal with the edge of the bracket ...

Page 462: ...the new style Entrance Guide Plate A1533901 See illustration on page 4 ADDITIONAL INFORMATION The Entrance Seal Ass y shown in the illustration has been assigned a Part Number to make the replacement of the seals easier Please refer to page 2 of 4 for the positions of the seals 2 20 C3 Rear Front Upper Guide A 0 0 5 mm B 0 2 mm A1533075 20 Continued IMPORTANT DO NOT remove these screws IMPORTANT U...

Page 463: ... NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1533899 A1533901 Entrance Guide Plate 1 1 3 S 45 31 43 31 A1533591 Mylar 17 x 335 0 1 3 S 45 34 43 33 DENOTES NEW ITEM UNITS AFFECTED All FT5035 5535 4027 4527 4022 4522 copiers manufactured after Serial Number A3626080001 A3696080001 A3636890125 A3716890286 A3646890163 and A3726890054 respectively will have t...

Page 464: ...material gets caught between the Drum and the outside Entrance Seal A Figure 2 3 Glue is transferred to the OPC surface from adhesive backed throughput materials labels etc or from the backside of the Development Entrance Seal Occasionally the glue is then transferred to the Entrance Seal when the drum turns in reverse This results in the deformation of the Entrance Seal on the Development Unit NO...

Page 465: ...1 Replace the seals AA152333 AA152334 with new ones Be sure to first clean the areas where the seals will be attached Continued A A Align the edge of the seal with the edge of the bracket 0 1mm 2 AA150382 20 AA150231 2 AA150382 AA152333 AA152334 Align the edge of the seal with the edge of the bracket ...

Page 466: ...the new style Entrance Guide Plate A1533901 See illustration on page 4 ADDITIONAL INFORMATION The Entrance Seal Ass y shown in the illustration has been assigned a Part Number to make the replacement of the seals easier Please refer to page 2 of 4 for the positions of the seals 2 20 C3 Rear Front Upper Guide A 0 0 5 mm B 0 2 mm A1533075 20 Continued IMPORTANT DO NOT remove these screws IMPORTANT U...

Page 467: ... NUMBER DESCRIPTION QTY INT MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1533899 A1533901 Entrance Guide Plate 1 1 3 S 45 31 43 31 A1533591 Mylar 17 x 335 0 1 3 S 45 34 43 33 DENOTES NEW ITEM UNITS AFFECTED All FT5035 5535 4027 4527 4022 4522 copiers manufactured after Serial Number A3626080001 A3696080001 A3636890125 A3716890286 A3646890163 and A3726890054 respectively will have t...

Page 468: ...depending on the environmental conditions in which the copier is installed The adjustment levels f or the new SP Mode are as follows SP3 801 0 OFF 1 Process Control Cycle is performed every 1K copies Default 2 Process Control Cycle is performed every 500 copies 3 Process Control Cycle is performed every 200 copies 2 Optics Filters have been registered as service parts for machines which are locate...

Page 469: ...achines that usually make copies continuously under the following conditions FT5035 5535 Less than500 copies FT4027 4527 4022 4522 Less than600 copies If you install the Optics Filters on a machine that will be run in excess of the quantities listed a bove set the copy limit SP5 017 to the maximum numbers This is because the temperature of the Exposure Glass may be much higher if the lamp voltage ...

Page 470: ...nding on the environmental conditions in which the copier is installed The adjustment levels f or the new SP Mode are as follows SP3 801 0 OFF 1 Process Control Cycle is performed every 1K copies Default 2 Process Control Cycle is performed every 500 copies 3 Process Control Cycle is performed every 200 copies 2 Optics Filters have been registered as service parts for machines which are located in...

Page 471: ...22 machines that usually make copies continuously under the following conditions FT5035 5535 More than500 copies FT4027 4527 4022 4522 More than600 copies If you install the Optics Filters on a machine that will be run in excess of the quantities listed a bove set the copy limit SP5 017 to the maximum numbers This is because the temperature of the Exposure Glass may be much higher if the lamp volt...

Page 472: ...mage the Hot Roller PRODUCTION COUNTERMEASURE An additional step has been added during production to ensure that the screws have sufficient torque applied FIELD COUNTERMEASURE At the next service visit ensure that the three screws indicated in the illustration are not loose UNITS AFFECTED All FT4022 4522 4027 4527 5035 5535 manufactured since August 1996 have had the production countermeasure list...

Page 473: ... respectively will have the new style Side Fences installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CA...

Page 474: ... NEW PART NO DESCRIPTION QTY PAGE ITEM AF010066 A1342953 Paper Tray 1 1 15 8 A1342960 Paper Talon 0 1 15 21 DENOTES NEW ITEM UNITS AFFECTED All FT5035 5535 copiers manufactured after Serial Number A3626080001 and A3696070570 respectively will have the Paper Talon installed during production Serial Number information for the FT4022 4522 4027 4527 copiers was not available at time of publication CUS...

Page 475: ... AA151998 Cushion 10 x 30 x 5 1 0 13 28 13 13 UNITS AFFECTED All FT5035 5535 4027 4527 4022 4522 copiers manufactured after Serial Number A3626080001 A3696080001 A3636870121 A3716870214 A3646870176 and A3726860458 respectively will not have the Cushion 10 x 30 x 5 installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT b...

Page 476: ...as shown below UPDATE NO 3 EXIT SENSOR BRACKET The Exit Sensor Bracket and Upper Guide Plate Assembly have been added to the FT5035 5535 Parts Catalog Also the Part Number for the Upper Guide Plate has been changed REFERENCE INCORRECT PART NO NEW PART NO DESCRIPTION QTY PAGE ITEM A1534451 A1534452 Upper Guide Plate 1 1 58 6 A1534456 Exit Sensor Bracket 0 1 58 29 A1534451 Upper Guide Plate Ass y 0 ...

Page 477: ...CORRECT DESCRIPTION PAGE ITEM A1532110 Transfer Roller Bracket Charge Roller Assembly 39 2 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines...

Page 478: ... 49 5 47 5 47 5 AA082063 AE031028 Bushing 4MM 2 2 1 49 6 47 6 47 6 UNITS AFFECTED All FT40274527 5035 5535 copiers manufactured after Serial Number A363702XXXX A371702XXXX A3627010001 and A3696120205 respectively will have the new style Cleaning Roller Bushings installe d during production Serial Number information for the FT4022 4522 copiers was not available at time of publication UPDATE NO 2 TO...

Page 479: ...ller Paddle Roller Replacement Procedure 1 Remove Development Unit 2 Remove the Toner Hopper from the Development Unit 3 Remove the three 3 seals A and the one seal B from the Development Unit 4 Remove the Entrance Seal Assembly C 2 screws D 5 Remove the Side Bracket E 2 screws F Continued CUSTOMER SERVICE GROUP n MECHANICAL q PAPER PATH q ELECTRICAL q OTHER Note This copy intended as master of or...

Page 480: ... Roller Ass y I and replace the Bushings J and V rings K NOTE Make sure that the V ring is in the proper position as shown in the illustration 8 Re assemble Development Unit DO NOT LOOSEN THIS SCREW Continued DO NOT LOOSEN THESE SCREW Entrance Seal Ass y C A1533075 Side Bracket E Screw F Seal A AA150382 Screw D Seal B AA150231 Screws G I J K K J H ...

Page 481: ... components in the Development Unit This Information should be incorporated in all existing Parts Catalog documentation REFERENCE NEW PART NUMBER DESCRIPTION QTY MODEL FT5535 5035 FT4027 4527 4522 4022 PAGE ITEM PAGE ITEM A1533063 Paddle Roller Ass y 1 39 27 37 27 AA080200 Bushing 6 X 12 X 11 2 39 28 37 28 AA152331 V ring 2 39 29 37 29 Denotes New item 28 27 29 29 28 ...

Page 482: ...image areas Once on the Drum toner and talc compound is combined and pressed down by the Transfer Belt and Charge Roller This leads to a gradu al build up on the Drum surface The talc on the Drum surface is then carried to the Development Unit and then accumulates there This accumulation of talc accelerates the filming problem in an area the wi dth of the Development Roller SOLUTION Change the typ...

Page 483: ...XXXX A371610XXXX and A3696080001 will have the new style Upper Exit Roller installed during production INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in ...

Page 484: ...Bottle Unit Holder 1 37 35 35 35 INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be ins...

Page 485: ...027 4522 copiers manufactured after Serial Number A3696110001 A371611XXXX and A372611XXXX respectively will have the new style Bottom Pressure Plate installed during production UPDATE NO 3 TRAY BOTTOM LIFT SHAFT LEVER Due to part standardization the following parts have been changed NOTE These parts are interchangeable as a set REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A13429...

Page 486: ...3F 4000 0 1 9 40 A1595460 Printed Circuit Board 0 1 9 34 9 32 A1605461 Printed Circuit Board 0 1 9 35 9 33 A1595465 Printed Circuit Board 0 1 9 36 9 34 A1605466 Printed Circuit Board 0 1 9 37 9 35 12041347 Push Switch B3F 1000 0 1 9 38 9 36 12041294 Key Switch B3F 4000 0 1 9 39 9 37 12041347 6mm x 6mm Print Key Switch on the PCB 12041294 12mm x 12mm Print Key Switch NOTE The following table shows ...

Page 487: ...ble FT4527 4027 Operation Panel Ass y Print Circuit Board AG011314 A1595460 AG011315 A1605461 AG011316 A1595465 AG011317 A1605466 AG011321 A1595460 AG011322 A1605461 FT4522 4022 AG011323 A1595460 AG011325 A1605461 AG011324 A1595465 AG011326 A1605466 AG011327 A1595460 AG011328 A1605461 ...

Page 488: ...2 4522 Parts Catalog This item is already listed correctly on page 37 item 3 This information should be i ncorporated into all existing FT4027 4527 4022 4522 Parts Catalog documentation REFERENCE PART NO DESCRIPTION QTY PAGE ITEM A1533200 Toner Hopper Ass y 1 0 35 CUSTOMER SERVICE GROUP q MECHANICAL q PAPER PATH q ELECTRICAL q OTHER Note This copy intended as master of original for reproduction of...

Page 489: ...ss of Optical Filter This information should be incorporated into all existing FT5035 5535 4027 4527 4022 4522 Parts Catalog documentation REFERENCE OLD PART NO NEW PART NO DESCRIPTION QTY INT PAGE ITEM A1531674 A2041674 Shield Glass Guide 2 2 3 73 19 A1531677 A2041677 Optical Filter 1 1 1 73 21 AC015017 Shield Glass 1 0 73 23 NOTE When the Optical Filter is changed from A1531677 to A2041677 remov...

Page 490: ...tion INTERCHANGEABILITY CHART 0 OLD and NEW parts can be used in both OLD and NEW machines 2 NEW parts CAN NOT be used in OLD machines OLD parts can be used in OLD and NEW machines 1 NEW parts can be used in OLD and NEW machines OLD parts CAN NOT be used in NEW machines 3 OLD parts CAN NOT be used in NEW machines NEW parts CAN NOT be used in OLD machines 3 S Must be installed as a set on units man...

Page 491: ... copies are made An electrical arc occurs when the amount of the static elect rical charge reaches the threshold level and this arcing causes the SC condition SOLUTION Using a multimeter ensure the rollers and the Guide Plate are grounded Replace the appropriate bru shes if the rollers or the Guide Plate are not properly grounded NOTE Check the resistance with the Fusing Unit in the machine CUSTOM...

Page 492: ...sed on the A157 copier The A210 copier is based on the A159 copier The A211 copier is based on the A160 copier Only the differences from the base copiers are described in the following pages Therefore this documentation should be treated as an insert version of the base copier s service manual although it has a separate binder It should always be utilized together with the base copier s service ma...

Page 493: ...PRODUCT CODE COMPANY RICOH SAVIN GESTETNER A207 FT5840 9400D CMR402 A208 FT5632 9032 CMR321 A211 FT5832 9032D CMR322 A206 FT5740 N A 9400L CMR401A A204 FT5640 N A 9400 N A CMR401 A210 FT5732 N A 9032L CMR321A ...

Page 494: ...m up period is completed 6 The metal parts inside the fusing unit become extremely hot while the copier is operating Be careful to avoid touching those components with your bare hands HEALTH SAFETY CONDITIONS 1 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 ...

Page 495: ...nd organic photoconductor according to local regulations These are non toxic supplies 3 Dispose of replaced parts in accordance with local regulations 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 A207 A208 A211 ii SM ...

Page 496: ... depending on the customer s requests Pg 1 19 Three possible corrections can be selected depending on the customer s requests Pg 2 10 3 Toner Supply Control The amount of toner supplied per unit of time has been increased to meet the increase in the copier process speed 0 217 mg ms for A204 series 0 183 mg ms for A208 series Pg 1 20 The amount of toner supplied per unit of time is as follows 0 183...

Page 497: ...ame level as for the base copier at normal temperatures This is why the drum rotation time correction is longer necessary as this correction was applied only at low temperatures Pg 1 23 Both the temperature and the drum rotation time are monitored to apply corrections to the drum charge roller during copying and when making a ID sensor pattern Pg 2 24 7 Toner End Recovery The toner end recovery de...

Page 498: ...aning Timing SP2901 The timing has been changed to achieve a better cleaning efficiency SP2 901 The default setting is 500 copies Cleaning is performed for 5 seconds Pg 1 29 SP2901 The default setting is 1 000 copies Cleaning is performed for 10 seconds Pg2 37 3 Cleaning Pad The shape of the cleaning pad B has been changed as shown This prevents waves from forming on the cleaning pads at the assem...

Page 499: ...7 A159 A160 85 V 200 W Pg 2 30 3 Optics Cooling Fans Rotating speed has increased to match the increase in the cpm A204 A206 A207 3 450 rpm A208 A210 A211 3 200 rpm Also the rotating temperature is 45 C for all models Pg 1 30 The rotating speed is as follows A153 A155 A156 3 200 rpm A157 A159 A160 3 200 rpm Rotating temperature as follows A153 A155 A156 45 C A157 A159 A160 40 C Pg 2 39 4 Scanner D...

Page 500: ...bracket A is installed on the right rear corner of the paper tray to prevent mis fed paper from falling into the back of the copier when the paper tray is pulled out IMAGE FUSING 1 Fusing Unit The fusing unit for the A204 A206 A207 copiers has been newly designed to meet the needs of a 40 cpm copier The A208 A210 A211 copiers basically take over the fusing unit used in the A153 A155 A156 copiers T...

Page 501: ...is used To prevent this from occurring the A204 A206 A207 copiers hot roller has been changed to a thicker metal Aluminum core type so it can hold heat during multi copy runs without the temperature falling too much The secondary fusing lamp is installed to achieve a faster warm up time Thickness of hot roller 7 0 mm Pg 1 35 Two fusing lamps are controlled separately to keep the operating temperat...

Page 502: ...his function can be performed by pressing a key on the operation panel This function was only available by accessing a UP mode 6 Reduce Enlarge Key The Reduce key and the Enlarge key are placed at the center of the operation panel for easier user operation Both keys are placed behind the operation panel cover 7 Image Shift Margin Adjustment The front and back margins are independently adjustable O...

Page 503: ...Section 1 Overall Machine Information ...

Page 504: ...s A4 11 x 81 2 sideways LCT A6 51 2 x 81 2 lengthwise By pass Duplex Copying Maximum A3 11 x 17 Minimum A5 81 2 x 51 2 sideways Copy Paper Weight Paper tray 52 128 g m2 14 34 lb By pass 52 157 g m2 14 42 lb LCT 52 128 g m2 14 34 lb Duplex copying 64 105 g m2 17 24 lb Reproduction Ratios 4 Enlargement and 6 Reduction A4 A3 Version LT DLT Version Enlargement 200 141 122 115 200 155 129 121 Full size...

Page 505: ...40 kW 1 35 kW 1 40 kW Copying 1 15 kW 1 21 kW 0 90 kW 1 00 kW Warm up 1 21 kW 1 23 kW 0 98 kW 1 00 kW Stand by 0 18 kW 0 20 kW 0 16 kW 0 18 kW NOTE Full System Copier ARDF A663 Paper Tray Unit A549 20 Bin S S A664 Noise Emission A204 A206 and A207 copiers A208 A210 and A211 copiers Copier Only Copier Only 1 Sound Pressure Level Operator position 64 dB A 63 dB A Standard position 59 dB A 58 dB A 2 ...

Page 506: ...19 Warm up Time A204 A206 and A207 copiers Less than 250 seconds 20 C A208 A210 and A211 copiers Less than 110 seconds 20 C First Copy Time Paper Feed Station A4 11 x 81 2 sideways A204 A206 and A207 copiers A208 A210 and A211 copiers 1st Tray 4 4 s except for A207 4 9 s except for A211 2nd Tray 4 9 s 5 4 s By pass 4 4 s 4 7 s LCT 4 4 s 4 9 s NOTE In A207 and A211 copiers the 2nd tray in the above...

Page 507: ...000 sheets NOTE Paper tray 500 sheets or less than 53 mm stack height By pass feed 40 sheets or less than 4 mm stack height LCT 1 000 sheets or less than 120 mm stack height Duplex Tray Capacity A207 A211 50 sheets 30 sheets for A3 11 x17 81 105g m2 21 5 27 9 lb paper Toner Replenishment Cartridge exchange 415 g cartridge Optional Equipment Platen cover Document feeder Paper tray unit with two pap...

Page 508: ... Original length sensor for 11 x 15 size paper only for LT DLT version ADS sensor for particular types of red original Specifications are subject to change without notice Overall Machine Information SPECIFICATIONS SM 1 5 A207 A208 A211 ...

Page 509: ...2 MACHINE CONFIGURATION 2 1 COPIER A204V500 wmf MACHINE CONFIGURATION A207 A208 A211 1 6 SM ...

Page 510: ...MENT Accessories new for A204 A206 A207 A208 A210 and A211 NOTE ST20 A664 STAPLE TYPE F ST29 A658 STAPLE TYPE E ST10 A555 STAPLE TYPE E A204V501 wmf Overall Machine Information MACHINE CONFIGURATION SM 1 7 A207 A208 A211 ...

Page 511: ...he same as the A207 copier except that the A204 does not have a duplex tray or an LCT 2 The A206 copier is the same as the A207 copier except that the A206 does not have a duplex tray 8 7 5 6 9 10 11 12 13 14 21 20 19 15 16 17 18 22 31 38 37 36 35 34 33 32 4 1 2 3 23 30 29 28 27 26 25 24 A204V502 wmf MECHANICAL COMPONENT LAYOUT A207 A208 A211 1 8 SM ...

Page 512: ...pier except that the A208 does not have a duplex tray or an LCT 2 The A210 copier is the same as the A211 copier except that the A210 does not have a duplex tray 8 7 5 6 9 10 11 12 13 14 21 20 19 15 16 17 18 22 31 38 37 36 35 34 33 32 4 1 2 3 23 30 28 27 26 25 24 29 A204V503 wmf Overall Machine Information MECHANICAL COMPONENT LAYOUT SM 1 9 A207 A208 A211 ...

Page 513: ...lers 18 Feed Roller 19 Pick up Roller 20 Separation Roller 21 Large Capacity Tray 22 Vertical Transport Rollers 23 Paper Feed Roller 24 Friction Pad 25 Duplex Friction Roller 26 Duplex Feed Roller 27 Jogger Fence 28 Transfer Belt 29 Transfer Belt Cleaning Blade 30 Lower Paper Tray 31 End Fence 32 Entrance Rollers 33 Pick off Pawls 34 Pressure Roller 35 Hot Roller 36 Junction Gate 37 Hot Roller Str...

Page 514: ...CB9 Duplex Control Duplex machines only Controls the operation of the duplex tray 60 PCB10 Liquid Crystal Display A207 machines only Controls the guidance display and displays guidance for machine operation 6 PCB11 LCT Interface LCT machines only Interfaces the LCT control signal between the main board and the LCT 100 Motors M1 Main Drives the main unit components 85 M2 Toner Bottle Drive Rotates ...

Page 515: ... by pass feed table 26 S2 By pass Feed Paper End Informs the CPU that there is no paper in the by pass tray 30 S3 Upper Tray Paper End Non duplex machines only Informs the CPU when the upper paper tray runs out of paper 48 S4 Upper Relay Detects the leading edge of paper from the upper tray to determine the stop timing of the upper paper feed clutch and detects misfeeds 105 S5 Upper Tray Upper Lim...

Page 516: ...e CPU when the 3rd scanner is at the home position 23 S19 Original Length 2 Detects the length of the original This is one of the APS Auto Paper Select sensors 20 S20 Fusing Exit Detects misfeeds 42 S21 Platen Cover Informs the CPU whether the platen cover is up or down related to APS ARE functions ARE Auto Reduce and Enlarge 15 S22 Toner End Instructs the CPU to add toner to the toner supply unit...

Page 517: ... upper paper tray and detects when the tray has been closed The upper tray switch has been eliminated 24 SW4 Lower Tray Paper Size Determines what size of paper is in the lower paper tray and detects when the tray has been closed The lower tray switch has been eliminated 33 SW5 Vertical Guide Set Non LCT machines only Detects whether the vertical guide is open or not 31 SW6 LCT Cover 1 LCT machine...

Page 518: ...OL3 LCT Pick up LCT machines only Picks up paper from the LCT 96 SOL4 Upper Tray Pick up Non duplex machines only Controls the up down movement of the pick up roller in the upper paper tray A208 210 211 have the components needed for an FRR mechanism 77 SOL5 Lower Tray Pick up Controls the up down movement of the pick up roller in the lower paper tray A208 210 211 have the components needed for an...

Page 519: ...nd the drum 35 H2 Optics Anti condensation option Turns on when the main switch is off to prevent moisture from forming on the optics 43 H3 Lower Tray option Turns on when the main switch is off to keep paper dry in the lower paper tray 34 Thermistors TH1 Main Fusing Monitors the temperature at the central area of the hot roller 66 TH2 Secondary Fusing A208 A210 A211 machines only Monitors the tem...

Page 520: ...The copier will not operate until it is installed N A Others CB1 Circuit Breaker 220 240 V machines only Provides back up high current protection for electrical components 9 TR1 Transformer 220 240 V machines only Steps down the wall voltage to 100 Vac 7 CC1 This has been eliminated from all models RY1 Relay Disables heater when copier is on 106 Overall Machine Information ELECTRICAL COMPONENT DES...

Page 521: ...208 A210 and A211 have been changed to the FRR feed system all models carry the same type of drive layout 1 Upper Paper Feed Clutch Gear A207 A211 only 2 Lower Paper Feed Clutch Gear 3 Relay Clutch Gear 1 2 3 A204V504 wmf PAPER FEED DRIVE LAYOUT A207 A208 A211 1 18 SM ...

Page 522: ...ndicated above will be applied to each manual I D level Selecting halftone mode will automatically shift the unit from auto imnage density mode to manual image density 6 2 ADS CORRECTION Five possible corrections can be selected the base copier has only three ADS correction ADS Density SP5 106 Development Bias Correction Voltage Setting Copy Density 0 Darkest 816 x AR 0 85 60 1 Darker 816 x AR 0 7...

Page 523: ...lowing formula Toner CL on time ms S x AT x TSC 100 TS Formula 1 where S Copy paper size cm2 AT Amount of toner developed on the latent image per unit area 0 7 mg cm2 constant TSC Toner supply coefficient TS Amount of toner supplied per unit of time 0 217 mg ms for A204 A206 and A207 copiers 0 183 mg ms for A208 A210 and A211 copiers PROCESS CONTROL A207 A208 A211 1 20 SM ...

Page 524: ...ensor output cannot be adjusted to 2 5 0 1 V Fixed Supply Mode Manual ID level or ADS indicator blinks TD Sensor VT Measurement Error If VT 4 0 V or VT 0 3 V during VT detection Fixed Supply Mode Manual ID level or ADS indicator blinks Drum Charge Thermistor Error Temperature detected by the drum charge thermistor is below 0 C or above 60 C Fixed Supply Mode None Abnormal Drum Charge Thermistor Ou...

Page 525: ...lopment bias corrections will both be 80 V VR correction also depends on the current VSP pattern ID correction that is being used If development bias has been increased by ID correction the VR correction may be smaller in some cases to take this into account This is shown by both the table above and the following diagram Using the same example to illustrate this but with an ID correction of 80 V t...

Page 526: ... A211 copiers The new drum charge roller needs only about half the correction voltage used for the base copier Also the level of correction needed for the lowest temperature point 5 C is about the same as the normal room temperature point for the base copier A In the base machine rotation time correction was only needed for low temperatures where the temperature correction was large In the new mac...

Page 527: ...e Roller Temperature C Temperature Correction VSP Pattern Copying 35 0 T 53 57 0 28 0 T 35 0 83 5 3 9T 211 0 4 4T 10 0 T 28 0 217 6 8 7T 410 0 11 5T T 10 0 130 0 295 0 A208 A210 and A211 Drum Charge Roller Temperature C Temperature Correction VSP Pattern Copying 35 0 T 47 61 0 29 0 T 35 0 51 0 2 8T 173 0 3 2T 10 0 T 29 0 199 1 7 9T 355 5 9 5T T 10 0 120 0 260 0 PROCESS CONTROL A207 A208 A211 1 24 ...

Page 528: ... checks for toner for a total of 14 seconds stopping 2 seconds after the toner supply clutch stops When the toner supply clutch stops any toner present is likely to drop into the development unit which will be detected during the final 2 seconds of detection time This will decrease the chances of a mis detection when a new toner bottle has been installed by the customer ON OFF 10 2 2 2 5 5 Toner S...

Page 529: ...ner Present t 7s Toner Supply Clutch Toner Bottle Drive Turn On Toner End Detection Is Toner Present t 12s Drum Drive Development Clutch Toner Supply Clutch Toner Bottle Drive Motor Turn Off Toner End Detection Is Toner Present t 14s Yes No Yes No Yes No Yes Yes Yes Yes No Yes Components Turn Off Toner End Near End Condition is Canceled Components Turn Off Toner End Near End Condition is Canceled ...

Page 530: ...inal ARDF mode or once when the key is pressed Platen mode Development bias New exposure lamp ADS sensor after SP4 001 Exposure lamp voltage adjustment or optics cleaning Every 1 000 copies VADS pattern is stored ID correction and Toner density control ID sensor VSG New drum ID sensor or ID sensor cleaning At the start of each copy job Dev bias Toner supply clutch ON time VSP About every 10 copies...

Page 531: ...one Mode B VSP Pattern Detection 300 BP ID correction 1370 Temperature correction CP 0 VR Pattern Detection 0 1500 VR correction Temperature correction C 0 VL Pattern Detection Forced VL Detection BL VR correction VBL ID Vexp VL Detection BL 25 VR correction VBL ID Vexp VL correction Non Image Area 200 VR correction VBL ID 0 0 Auto ADS Gain Adjustment 0 0 Vexp VL correction NOTE B Development bias...

Page 532: ...For 2 seconds at the end of every job 2 For 5 seconds after the copy job interval set by SP2 901 SP2 901 setting 0 Every 1 000 copies 5 seconds 1 Every 500 copies 5 seconds new default 2 Every 200 copies 5 seconds 3 Every 100 copies 5 seconds The effect of the change in the default setting is to do the cleaning more frequently Overall Machine Information DRUM SM 1 29 A207 A208 A211 ...

Page 533: ...nged Both models now have two fans this is because the cpm for the A207 A210 A211 models has been increased from the previous models 27 32 Also the rotating speed has been changed as follows A204 A206 A207 A207 A210 A211 Rotating speed 3 450 rpm 3 200 rpm Rotating temperature 45 C 45 C Number of fans 2 2 The rotating speed of 3 200 rpm is as same as for the A153 A155 A156 copiers 8 2 SCANNER DRIVE...

Page 534: ...S SAMPLING DURING COPYING The position of the sampling area has been changed in the base copier it was 60 mm from the edge and 38 mm wide A204D511 wmf Overall Machine Information OPTICS SM 1 31 A207 A208 A211 ...

Page 535: ...er trays that hold 500 sheets of paper Paper can also be fed using the by pass feed table C which uses the feed mechanism of the LCT feed station The by pass feed table can hold 40 sheets of paper All feed stations use the FRR feed system The top sheet of paper separates from the stack and is fed to the relay rollers then to the registration rollers There are two relay sensors one located just und...

Page 536: ...wer connector the shape has changed and uses the same parts hot roller etc 2 7 6 4 5 3 10 9 8 1 13 11 12 A204D513 wmf 1 Thermofuse 2 Oil Supply Roller 3 Oil Supply Roller Cleaning Brush 4 Main Fusing Lamp 5 Pressure Springs 6 Hot Roller 7 Pressure Roller 8 Cleaning Roller 9 Secondary Fusing Lamp 10 Fusing Exit Rollers 11 Fusing Exit Sensor 12 Hot Roller Strippers 7 pcs 13 Thermistor Overall Machin...

Page 537: ...ne tube As the temperature of the hot roller rises the PTFE tube contracts and squeezes the oil soaked paper and the oil comes out through the coating The oil supply roller cleaning brush C under the oil supply roller removes the toner and paper dust accumulated on the oil supply roller The oil supply roller shaft is installed on a one way bushing D to prevent collected toner from returning to the...

Page 538: ...the main switch is turned on When reheating the unit after exiting from the energy saver mode The new hot roller s metal core is thicker than the base copier s hot roller s The new roller holds heat much better to allow multicopying at the higher cpm of this model without the hot roller temperature dropping too far However it takes a lot longer to warm up after switching on see the Warm up Time in...

Page 539: ...letely and evenly the roller has a thicker metal core and to distribute the oil During fusing idling the temperature is kept at 185 C When fusing idling is finished the copier enters the ready condition The CPU keeps the temperature at 185 C by turning the main fusing lamp off and on The lamp is turned off at 190 C and on at 180 C If the fusing lamp turns on while the exposure lamp is on the power...

Page 540: ...07 copier 1 3 Optional Zoom Function Decal 1 4 Optional Margin Adjustment Function Decal 1 5 Combine Originals Explanation Decal except for the A207 copier 1 6 Receiving Tray 1 7 Operating Instructions except for 27 machines 1 8 User Survey Card 17 machines only 1 9 New Equipment Condition Report 1 10 Cushion 1 Overall Machine Information INSTALLATION SM 1 37 A207 A208 A211 ...

Page 541: ...11 2 COPIER INSTALLATION PROCEDURE CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets A204I516 wmf INSTALLATION A207 A208 A211 1 38 SM ...

Page 542: ...f not skewed image may result 1 Remove the scanner lock pin A and red tag B as shown 2 Remove the strips of tape and the sheet of paper C Also for A206 207 A210 A211 copiers remove the strip of tape on the LCT D 3 Pull out the paper tray E and remove the strips of tape and the bottom plate stopper F Then install the paper tray in the copier 1 tray for duplex machines and 2 trays for non duplex mac...

Page 543: ...er D 3 Open the upper duplex guide plate E and remove the strips of tape F 4 Open the lower duplex guide plate G and remove the styrofoam support H and the sheet of paper I 5 Install the duplex tray in the copier F I G B H C B A F E D A207 copier A204I503 wmf F I G B H C B A F E D A211 copier A204I504 wmf INSTALLATION A207 A208 A211 1 40 SM ...

Page 544: ...nterclockwise to lower the transfer belt unit Then remove the cushion sheet E 9 Remove the blade release wedge F together with the pick off pawl release mylar G 10 Return the A1 lever to the set position A204 A206 A207 copiers C B A B A204I505 wmf F G E A204I506 wmf D A B A208 A210 A211 copiers A204I507 wmf Overall Machine Information INSTALLATION SM 1 41 A207 A208 A211 ...

Page 545: ...y D and swing out the bottle holder assembly D 13 Remove the knob screw E and disconnect the white connector F 14 Pull down the development unit lock lever G from under the plate and pull out the development unit H Then place it on a clean sheet of paper D B A C A204I508 wmf H F E G A204I509 wmf INSTALLATION A207 A208 A211 1 42 SM ...

Page 546: ...ning developer and rotate the gear again NOTE To prevent the developer from spilling do not rotate the gears in the other direction 17 Remount the toner supply unit on the development unit 2 screws and connect the white connector NOTE Make sure that the positioning rib E sits in the groove F 18 Install the development unit in the copier 1 knob screw and 1 connector A B F E A204I510 wmf D C A204I51...

Page 547: ... the bottle holder lock lever so that the knob screw holes are aligned 3 Secure the bottle holder lock lever with the knob screw CAUTION Do not swing the bottle holder assembly all the way into its original position in the machine without sliding and locking it into position exactly as described above Otherwise the assembly will be damaged 21 Install a toner bottle by following the instructions pl...

Page 548: ...r 2 and press the key 3 Enter 207 and press the key 4 Press the key NOTE The machine will automatically stop when compulsory toner supply is completed It takes about 30 seconds 5 Compulsory toner supply must be performed twice in order to supply enough toner to the toner hopper so press the key again 26 A207 copier only Select the proper language for the guidance display as follows 1 Press the key...

Page 549: ...y by following the procedure shown in Installation section 2 3 in the base copier manual Paper Size Selection and in Service Tables SP5 019 Paper Size Setting 31 Load paper into the paper trays and the copy tray 32 Attach the appropriate paper size decals A to the paper trays Also A207 A211 copiers only attach the duplex decal to the duplex tray NOTE Paper size decals are used also for the paper t...

Page 550: ...crews and slide it to the left 35 All models except the A207 Attach the symbol explanation decal D to the top cover as shown If the ARDF will be installed stick the decal on the ARDF exit cover Refer to the ARDF installation procedure 36 Check the copy quality and machine operation B A C D A204I515 wmf Overall Machine Information INSTALLATION SM 1 47 A207 A208 A211 ...

Page 551: ...k the accessories against the following list Description Q ty 1 New Equipment Condition Report Multi language 1 2 Installation Procedure English 1 3 Stud Screw 2 4 Philips Screw with Flat Washer M4 x 10 2 5 Sponge Retainer 1 INSTALLATION A207 A208 A211 1 48 SM ...

Page 552: ...as shown NOTE When mounting the ARDF hold it by hand as shown in the illustration Holding it in another way may damage the ARDF 5 Screw the two stud screws E into the holes F and tighten them 6 Remove the plug J from the rear of the copier 7 Connect the connectors G into the socket on the rear of the copier 8 Attach the symbol explanation decal H and the combine originals explanation decal I to th...

Page 553: ...ion 2 4 Entrance Guide Mylar for A204 A206 A207 copiers 1 5 Entrance Guide Mylar for A208 A210 A211 copiers 1 6 Proof Tray 1 7 Caster Stopper 2 8 Relay Guide 1 9 Philips Pan Head Screw M4 x 12 4 10 Philips Pan Head Screw M4 x 6 2 11 New Equipment Condition Report Multi language 1 12 Staple Position Decal 1 13 Installation Procedure English 1 INSTALLATION A207 A208 A211 1 50 SM ...

Page 554: ... in order to avoid any transport damage 3 A sorter adapter A568 is required to install this sorter stapler in the A208 A210 A211 copiers Before installing this sorter stapler please install the sorter adapter 1 Remove the strips of tape A and the cushions B 2 Open the front door and remove the inner cover C 3 screws 3 Remove the strips of tape D and remove the cushion E Then re install the inner c...

Page 555: ...the copier 6 Attach the entrance guide mylar D to the copier exit area as shown NOTE 1 The entrance guide mylar differs depending on the model 2 Align the edge E of the cover and the mylar B C A A204 A206 A207 copiers A664I503 wmf B C A A208 A210 A211 copiers A664I504 wmf D D E A204 A206 A207 copiers A664I505 wmf D E D A208 A210 A211 copiers A664I506 wmf INSTALLATION A207 A208 A211 1 52 SM ...

Page 556: ... D then lower the locking lever 10 Align and press the sorter stapler against the copier and secure them by raising the locking lever E 11 Secure the locking lever 1 screw F 12 Install the proof tray G 13 Connect the connectors H to the sockets at the rear of the copier A B D C A664I507 wmf G H E F A664I508 wmf Overall Machine Information INSTALLATION SM 1 53 A207 A208 A211 ...

Page 557: ...adjust it by placing caster stoppers A 15 Plug in the copier 16 Turn on the main switch of the copier and test the operation of the sorter stapler NOTE The copier automatically recognizes that the sorter stapler has been installed A A664I509 wmf INSTALLATION A207 A208 A211 1 54 SM ...

Page 558: ...ollowing list Description Q ty 1 Staple Position Decal 1 2 Chain 1 3 Cap Remover 1 4 Philips Pan Head Screw M4 x 14 5 5 New Equipment Condition Report Multi language 1 6 Installation Procedure English 1 7 Stepped Screw 1 Overall Machine Information INSTALLATION SM 1 55 A207 A208 A211 ...

Page 559: ...ll be transported to another location 2 Proper reinstallation of the shipping retainers is required in order to avoid any transport damage 3 A sorter adapter A568 is required to install this sorter stapler in the A208 A210 A211 copiers Before installing this sorter stapler please install the sorter adapter 1 Remove the strips of tape and the shipping retainers as shown 2 Open the front door B and ...

Page 560: ... the copier left cover with nippers 4 By releasing the open lever B of the sorter stapler remove the sorter stapler mounting frame C as shown A A658I502 wmf C B A658I503 wmf Overall Machine Information INSTALLATION SM 1 57 A207 A208 A211 ...

Page 561: ...w D NOTE When hooking the sorter stapler mounting frame on the left side of the copier make sure that the positioning hooks E on the frame are properly inserted in the positioning holes F in the copier 7 Install the sorter stapler G on the frame 2 hinge pins at the rear as shown 8 Tighten the M4 x 14 screw H NOTE This screw prevents the sorter stapler from falling down A E F B C D A658I504 wmf G A...

Page 562: ...sition decal D as shown 12 Plug in the copier 13 Turn on the main switch of the copier and test the operation of the sorter stapler NOTE The copier automatically recognizes that the sorter stapler has been installed A B D C A658I507 wmf Overall Machine Information INSTALLATION SM 1 59 A207 A208 A211 ...

Page 563: ...the Function column comments extra information are in italics 8 In the Settings column the default values are printed in bold letters 9 RDS means Remote Diagnostic System not available in these models CSS means Customer Support System only available in Japan 10 Type 1 A204 A206 and A207 copiers Type 2 A208 A210 and A211 copiers 12 1 1 Quick Reference The following is a quick reference list of the ...

Page 564: ...upply Ratio Detect Supply Mode 2 301 xxx Transfer Current Adjustments Factory Use Only Do not change the settings 2 801 Developer Agitation 2 802 Drum Charge Roller Temperature 2 812 Drum Reverse Rotation Adjustment 2 901 Drum Charge Roller Cleaning Interval 2 902 Not used Process Control 3 001 ID Sensor Initial Setting 3 002 ID Sensor Initial Setting Display 3 103 xxx ID Sensor Output Display 3 1...

Page 565: ...9 xxx Paper Size Set 5 021 xxx Duplex Priority Selection Energy Star 5 022 xxx Energy Star Selection 5 101 Auto Reset Time Setting 5 102 Auto Energy Saver Time Setting 5 103 Auto Tray Shift 5 104 A3 DLT Double Count 5 106 Image Density Level Correction ADS Correction 5 107 xxx Image Shift Margin Adjustment 5 108 Edge Erase Margin Adjustment 5 110 Center Erase Margin Adjustment 5 113 Coin Lock Inst...

Page 566: ...906 Manual Staple Reset Time Setting 5 907 Cover Mode Selection 5 908 Image Shift Erase Selection 5 909 10 key Zoom Size Magnification 5 910 Guidance Language Setting A207 copier only Peripherals 6 001 SADF Auto Reset Time Setting 6 003 Auto Sort Selection 6 005 Blank Copy for Last Odd Originals in Duplex 6 006 xxx DF Registration Adjustment 6 009 DF Free Run with Paper 6 010 Auto APS Select DF 6 ...

Page 567: ... Service Call 7 501 Total Jam Counter Copies Originals 7 502 Total Jams by Paper Size Note This is actually the Total Copy Paper Jam Counter The counter is not divided up by Paper Size 7 503 Total Original Jam Counter 7 504 xxx Total Jams by Location 7 505 xxx Total Original Jams by Location 7 801 xxx Main ROM Version Display 7 803 PM Counter Check 7 804 PM Counter Clear 7 807 001 SC Counter Clear...

Page 568: ... fusing idling starts when the detected temperature reaches the operating temperature 15 C For type 1 fusing idling starts when the detected temperature reaches the operating temperature 0 OFF 1 60 s 2 100 s 3 180 s 4 300 s Default 100 s Type 1 Default Off Type 2 The longer the selected fusing idling the longer time the machine takes to reach the ready condition After changing the setting turn the...

Page 569: ... of the hot roller 170 190 Default 175 1 C per step Range 170 C to 190 C 1 106 001 Fusing Temperature Display Main Fusing Lamp Displays the temperature C at the surface of the central area of the hot roller as measured by the thermistor The temperature in energy saving mode cannot be displayed as entering SP mode takes the machine out of this mode 1 106 002 Type 2 only Fusing Temperature Display S...

Page 570: ...ent for copying Adjusts the voltage applied to the drum charge roller during copying 0 32 Default 16 0 V The adjustment factor set with this SP mode is added to the base voltage 30 V per step Range Base voltage 480 V to Base voltage 480 V 2 002 001 to 2 002 002 Drum Charge Voltage Display Displays the voltage applied to the drum charge roller SP2 002 001 For copying SP2 002 002 For making VSP patt...

Page 571: ...el 7 is selected 2 203 Development Bias Adjustment for making VSP patterns Adjusts the development bias for making VSP patterns 1 10 Default 6 0 V The adjustment factor set with this SP mode is added to the base voltage 20 V per step Range Base voltage 80 V to Base voltage 100 V 2 206 001 to 2 206 002 Development Bias Display Displays the development bias SP2 206 001 Development bias used for copy...

Page 572: ...o Fixed Supply Mode Selects the toner supply ratio for Fixed Supply Mode For example if the user normally makes copies of originals that are about 6 black select the 6 setting for best results 1 3 2 6 3 10 4 15 2 214 TD Sensor Initial Setting Performs the TD sensor initial setting This SP mode controls the voltage applied to the TD sensor to make the TD sensor output 2 5 0 1 V After using SP2 214 ...

Page 573: ...emains on the drum it may get into the recycled toner If this is happening increase the reverse rotation by increasing the value of the setting 2 901 Drum Charge Roller Cleaning Interval Selects the drum charge roller cleaning interval Turn the copier main switch off and on after changing the setting 0 Every 1 000 copies 1 Every 500 copies 2 Every 200 copies 3 Every 100 copies The drum charge roll...

Page 574: ...is the value currently being used for VR correction 3 112 Forced VR Detection After the key is pressed forced VR detection is done For when to use this SP mode see Practical SP Mode Use Table 3 123 Drum Initialize This resets the following data regarding the OPC drum 1 VR correction level 2 VL correction level 3 OPC counter 4 T H correction level This SP mode must be used only when a new drum is i...

Page 575: ...000 copy process control cycles forcibly VSG initial adjustment VR detection VL detection VADS pattern adjustment This mode starts after the key is pressed 4 001 Exposure Lamp Voltage Adjustment Adjusts the exposure lamp voltage 0 5 V per step Range 50 0 V to 75 0 V 50 0 75 0 V Default 63 V For 115 V machines the actual applied voltage displayed value x 1 1412 After doing this SP mode ADS initial ...

Page 576: ...zontal Magnification Adjustment Adjusts the magnification perpendicular to the direction of paper travel 0 1 per step Range 1 6 to 1 6 See Replacement and Adjustment Copy Quality Adjustments for how to adjust 0 32 Default 16 4 102 Lens Error Correction Adjusts the lens position to correct for magnification in enlarge reduce mode 0 1 per step Range 0 8 to 0 8 0 16 Default 8 0 4 103 Focus Adjustment...

Page 577: ...onal APS Sensor LT version only Set this to 1 when installing the optional APS sensor 0 Not installed 1 Installed This SP mode is effective only for the LT version In the A4 version even if 1 is selected the setting is ignored 4 303 APS A5 HLT Detection Selects whether A5 HLT forced detection is done or not 0 NO 1 YES If YES is selected paper sizes that cannot be detected by the APS sensors are re...

Page 578: ...s whether the copier defaults to APS or manual mode when the main switch is turned on auto reset or mode cleared 1 APS 0 Manual Also see SP6 010 5 004 ADS Priority Selection Specifies whether the copier defaults to ADS or manual ID mode when the main switch is turned on auto reset or mode cleared 1 ADS 0 Manual 5 013 Counter Up Down Selection Selects whether the counter counts up or down 1 Up 2 Do...

Page 579: ... 60 1 second per step Range 1 999 If 0 is selected auto reset is disabled 5 102 Auto Energy Saver Time Setting Sets the time that the machine enters energy saver mode after entering the ready condition NA version 1 120 Default 15 Other versions 0 120 Default 1 1 minute per step If 0 is selected the energy saver mode is disabled except for NA version 5 103 Auto Tray Shift Selects whether auto tray ...

Page 580: ...se center mode A4 version 8 25 Default 20 LT version 0 32 1 00 Default 0 80 SP5 908 must be at 1 for this to have any effect A4 version 1 mm per step Range 8 mm to 25 mm LT version 0 01 per step Range 0 32 1 00 5 113 Coin Lock Installation Specifies whether coin lock is installed or not only for Japanese versions 0 Not installed 1 Installed 5 115 Duplex Image Shift Back Side Margin Specifies wheth...

Page 581: ...that user code is displayed in the reduce enlarge indicator Hold down the key to display the last three digits Use the and keys to check each user code counter 5 404 001 to 5 404 002 User Code Counter Clear Resets the user code counters SP5 404 001 Resets the counter for the user code that is now displayed in the reduce enlarge indicator SP5 404 002 Resets all the UC counters To reset the counter ...

Page 582: ...ecifies whether PM alarm mode is on or off 0 OFF 1 ON If PM alarm mode is on the manual ID level ADS indicator and copy counter blink when the PM counter reaches the PM interval 5 504 RDS CSS Alarm Level for Paper Jam Paper Jam Alarm Level Setting Used in Japan only Do not change the factory setting 5 505 RDS CSS Alarm Level for SC Service Call Alarm Level Setting Used in Japan only Do not change ...

Page 583: ...to input the telephone number of the service representative this is displayed when a service call condition occurs Maximum 16 digits Press the key to input a pause Press the key to delete the input telephone number 5 816 RDS CSS Function Setting For use in Japan only Do not change the factory setting 5 817 Repair Time Transmission For use in Japan only Do not change the factory setting 5 905 APS A...

Page 584: ... Finnish 11 Dutch 6 001 SADF Auto Reset Time Setting Sets the auto reset time for SADF mode 1 second per step Range 1 to 99 seconds 1 99 Default 5 6 003 Auto Sort Selection Specifies whether auto sort mode is on or off In auto sort mode when two or more originals are placed on the ADF sort mode is selected if the copy quantity is between 2 and 20 0 OFF 1 ON 6 005 Blank Copy for Last Odd Originals ...

Page 585: ...led 0 No sorter 1 A557 sorter 2 A556 sorter 3 Not used 4 A568 sorter adapter only After setting this SP mode the copier main switch must be turned off and on For the A555 A658 and A664 sorter stapler the setting does not have to be changed keep it at 0 6 102 Sorter Stack Limit Select which sorter stack limit to use 0 OFF 1 ON OFF Sorting and stacking can be done until the sorter tray cannot take a...

Page 586: ...pressing the key This is a general free run controlled from the copier For more detailed free run modes see the sorter manuals 7 001 Total Operation Time Display Displays the total operation time hours The first three digits are displayed in the reduce enlarge indicator Hold down the key to display the last three digits 7 002 Total Original Counter Display Displays the total number of scanned orig...

Page 587: ...e enlarge indicator Hold down the key to display the last three digits 7 204 001 to 7 204 008 Feed Unit Counter Displays the total number of copies fed from each feed unit The first three digits are displayed in the reduce enlarge indicator Hold down the key to display the last three digits 7 205 DF Counter Displays the total number of originals fed by the DF The first three digits are displayed i...

Page 588: ... indicator and the number of times this SC code has occurred is displayed in reduce enlarge indicator By pressing the and keys another service call number and its counter can be displayed 7 501 Total Jam Counter Copies Originals Displays the total number of copy jams plus original jams max 4 digits The first digit is displayed in the reduce enlarge indicator Hold down the key to display the last t...

Page 589: ...7 505 001 to 7 505 002 Total Original Jams by Location Displays the total original jams in the DF by location max 4 digits SP7 505 001 Feed in section SP7 505 002 Feed out section The first digit is displayed in the reduce enlarge indicator Hold down the key to display the last three digits SP Number Paper Jam Location Symbol SP7 504 001 Y SP7 504 002 A SP7 504 003 B SP7 504 004 C SP7 504 005 Z SP...

Page 590: ...er Check Displays the PM counter after the last PM max 6 digits The first three digits are displayed in the reduce enlarge indicator hold down the key to display the last three digits 7 804 PM Counter Clear Resets the PM counter The counter will be reset when you press the final key when entering this SP mode 7 807 001 SC Counter Clear Resets the total SC counter SP7 401 and the individual counter...

Page 591: ...Paper Size SP7 101 Total Copies by Magnification SP7 301 After pressing the final key when entering this SP mode the counters will be reset 7 811 DF Counter Clear Resets the DF counter SP7 205 After pressing the final key when entering this SP mode the counter will be reset Counters that are reset Counter check Operation Time SP7 001 Scanning Counter SP7 002 Copy Counter SP7 101 Total Sheets of Pa...

Page 592: ...he key SP Number Without Duplex With Duplex SP7 816 001 1st tray SP7 816 002 2nd tray 1st tray SP7 816 003 3rd tray 2nd tray SP7 816 004 4th tray 3rd tray SP7 816 005 5th tray 4th tray SP7 816 006 LCT LCT SP7 816 007 By pass By pass SP7 816 008 Duplex Overall Machine Information SERVICE PROGRAM MODE SM 1 89 A207 A208 A211 ...

Page 593: ...mage Shift Erase Selection 15 5 909 10 Key Zoom Size Magnification 16 5 107 Image Shift Margin Adjustment 17 5 108 Edge Erase Margin Adjustment 18 5 110 Center Erase Margin Adjustment 19 5 906 Manual Staple Reset Time Setting 20 6 001 SADF Auto Reset Time Setting 21 6 002 Not used 22 6 011 Thick Thin Original Mode Selection 23 5 402 User Code Counter Check 24 5 404 User Code Counter Clear 25 5 405...

Page 594: ...sure lamp and or optics do SP4 001 then 4 201 then 3 105 The toner shield glass has been eliminated AROUND THE DRUM Drum Charge Roller R R R Clean with the special cloth if necessary the cloth must be dry Drum Charge Roller Cleaner R R R Replace with the drum charge roller as a set Drum Charge Roller Terminal R R R Replace with the drum charge roller as a set ID Sensor C C C Blower brush After cle...

Page 595: ...rum Cleaning Blade Replacement Side Seal C C C Replace if necessary Cleaning Entrance Seal C C C Replace if necessary TRANSFER BELT UNIT Transfer Belt C C R C Spread setting powder See Transfer Belt Cleaning Blade Replacement Transfer Belt Cleaning Blade R R R Used Toner Tank C C C Blower brush or vacuum cleaner FUSING UNIT Fusing Entrance and Exit Guide Plates C C C Suitable solvent Fusing Lamps ...

Page 596: ... I Replace if necessary Green Filter C C C Dry cloth Scanner Guide Rails C C C Dry cloth ADS APS sensors C C C Blower brush Do SP4 201 after cleaning the ADS sensor Lens Block Guide Rail C C C C Dry cloth Dust Filter C C C Replace if necessary NOTE After cleaning the exposure lamp and or optics do SP4 001 then 4 201 then 3 105 The toner shield glass has been eliminated AROUND THE DRUM Drum Charge ...

Page 597: ...r By pass feed A208 only R Clean with water Replace these rollers and the torque limiter as a set Paper Feed Guide Plate C C C Alcohol or water Relay rollers C C C Alcohol or water Registration roller C C C Alcohol or water Bottom Plate Pad Paper tray By pass feed LCT C R R R Water CLEANING UNIT Drum Cleaning Blade R R R Spread setting powder See Drum Cleaning Blade Replacement Side Seal C C C Rep...

Page 598: ... L L L Mobil Temp 78 See Note 1 Feed Roller R R R Bottom Plate Pad R R R Mylars I I I Replace if necessary OTHERS Drive Belts I I I Replace if necessary EM 120 k 240 k 360 k NOTE SORTER ADAPTER A568 Type K Exit Drive Roller C Alcohol or Water Upper Roller C Alcohol or Water EM 120 k 240 k 360 k NOTE PAPER TRAY UNIT A550 A549 PS280 PS290 Pick up Feed Separation Rollers C C R C Water Replace these r...

Page 599: ... and Exit Rollers C C Alcohol or water Bins C C Alcohol or water Bin and Paper Sensors C C Blower brush Bushings L L Launa oil if bushings generate noise Helicam Wheels L L Grease G501 if worm gears generate noise Bin Cam Tracks L L Grease G501 if bin cam tracks generate noise 10 BIN SORTER STAPLER A555 ST10 Transport Roller C C Alcohol or water Bins C C Alcohol or water Bin and Paper Sensors C C ...

Page 600: ...he dust filter 1 Remove the drum and clean the ID sensor with a blower brush 2 Clean the pick off pawls 3 Clean the quenching erase and pre transfer lamps with a dry cloth Discharge any static electricity before putting them back 4 Put back the drum 5 Replace the drum charge roller drum charge roller cleaner and drum charge roller terminal and roller terminal Every 120 k A204 A206 A207 or 100 k A2...

Page 601: ...on and relay rollers for each paper feed station by pass feed and the LCT 3 Replace the bottom plate pad for each paper feed station by pass feed and the LCT 4 Clean the registration rollers 5 Development Unit every 120 k 6 Paper Feed every 120 k for each paper feed station Replace pick up feed and separation rollers for each paper feed station by pass feed and the LCT every 240 k A204 A208 only R...

Page 602: ...e the hot roller Lubricate the flange with Grease Barrierta JFE 55 2 6 Replace the pressure roller A204 A206 A207 copiers only 7 Replace the cleaning roller 8 Replace the oil supply roller and cleaning brush A204 A206 A207 copiers only 1 Inspect the mylars 2 Replace the feed roller and the bottom plate pad 3 Lubricate the clutch spring with Mobil Temp 78 1 Inspect the timing belts 8 Fusing Unit ev...

Page 603: ... Detection 4 SP4 001 Exposure Lamp Voltage Adj 5 SP4 201 Auto ADS Gain Adj 6 SP3 105 Forced VL Detection Perform these SP modes only if the exposure lamp has been replaced Make a copy of an OS A3 test chart at manual image density level 4 12 Development Unit every 120 k 13 Make a Copy 11 Exterior every 120 k PREVENTIVE MAINTENANCE SCHEDULE A207 A208 A211 1 100 SM ...

Page 604: ...ge Roller Cloth 1 5420 9516 Test Chart OS A3 10 pcs set 1 5420 9507 Digital Multimeter 1 A008 9502 Silicone Grease G40M 1 5442 9103 Launa Oil 1 5447 9078 Heat Resistant Grease MT 78 1 5203 9501 Grease 501 1 5442 9101 Setting Powder 1 A028 9300 Grease Barrierta JFE 55 2 1 Overall Machine Information SPECIAL TOOLS AND LUBRICANTS SM 1 101 A207 A208 A211 ...

Page 605: ...oving the fusing unit support the bottom of the fusing unit 1 Turn off the main switch and unplug the power supply cord 2 Remove the stopper bracket A 1 screw 3 Hold the fusing unit cover B while pushing the release lever C to the left and pull out the fusing unit until it stops 4 Push the release lever C again and remove the fusing unit completely A B C A204R500 wmf REPLACEMENT AND ADJUSTMENT A20...

Page 606: ...using unit See Fusing Unit Removal 2 Open the exit cover A 3 Remove the bracket B 2 screws 4 Replace the hot roller strippers C 1 spring and 1 stopper each A C B A204R501 wmf Overall Machine Information REPLACEMENT AND ADJUSTMENT SM 1 103 A207 A208 A211 ...

Page 607: ...ve the fusing unit See Fusing Unit Removal 2 Remove the fusing front cover A 1 screw 3 Remove the exit cover B as shown 2 screw 4 Replace the cleaning roller C 2 bushings A B C A204R502 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 1 104 SM ...

Page 608: ...rew 3 Disconnect the 4 connectors B 4 Remove the fusing upper unit C 4 screws 5 Replace the thermistor D 1 screw and 1 connector and the thermofuse E 2 screws NOTE When reinstalling connect the connectors B as shown C B B A A204R503 wmf E D A204R508 wmf Overall Machine Information REPLACEMENT AND ADJUSTMENT SM 1 105 A207 A208 A211 ...

Page 609: ...move the fusing front cover and the fusing upper unit See Thermistor and Thermofuse Replacement 3 Remove the lamp holders A 1 screw each 4 Replace the fusing lamps B NOTE Do not touch the fusing lamps with bare hands A B A204R504 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 1 106 SM ...

Page 610: ...ach end 4 Remove the gear B 1 E ring 5 Replace the hot roller C as shown 2 C rings 1 gear and 2 bearings NOTE The standard pressure spring position is the upper one D as shown The hot roller for the A204 A206 A207 has no dots at the end and it is heavier Lubricate the flange E of the hot roller with Grease Barrierta JFE 55 2 B C D A E A A204R505 wmf Overall Machine Information REPLACEMENT AND ADJU...

Page 611: ... roller 2 C rings and 2 bearings NOTE 1 When reinstalling the fusing entrance guide A use the center screw holes D if the standard paper thickness setting is acceptable Otherwise use the outer screws E tighten the screws while pushing the guide plate into the upper position for standard or thin paper For thick paper let the entrance guide plate drop to the lowest position 2 The standard pressure s...

Page 612: ...grounding harness B 1 screw 5 Remove the bracket C 2 screws 6 Replace the oil supply roller D and the oil supply roller cleaning brush E 2 screws and 2 bushings NOTE 1 The screws F and G are very similar When reinstalling do not mix them up F is longer than G 2 The front oil supply roller bushing H is a one way bushing When reinstalling do not mix it up with the rear bushing D F E C G A G H B A204...

Page 613: ...tion C When the bin lift bin drive motor is turning the timing sensor takes over 250 ms to change Possible Causes The timing sensor is defective The bin lift bin drive motor is defective The main control board is defective E722 Jogger Home Position Sensor Output Error A555 A658 A664 Definition C When the jogger bar moves forward the home position sensor takes over 100 ms to be deactivated When the...

Page 614: ... for one staple operation from home position to home position Possible Causes The stapler is defective The main control board is defective E940 Main Switch Error Definition A The detection mechanism is as follows The machine reaches the auto off time The solenoid mounted inside the main switch turns on for 3 seconds If the main switch does not turn off the solenoid is turned off for 1 seconds The ...

Page 615: ...4 A663 The DF64 A663 ARDF is based on the DF61 A548 ARDF Only the differences from the A548 are described in the following pages Refer to the A548 ARDF section inside the A153 A155 A156 A157 A159 A160 copier service manual for other information ...

Page 616: ...Maximum A3 11 x 17 Minimum B5 51 2 x 81 2 Weight 52 105 14 27 lb Original Feed Automatic feed ADF mode Manual feed one by one SADF mode Auto Reverse Feed ARDF mode Original Table Capacity 50 sheets at 80 g m2 21 lb Original Placement Face up first sheet on top Original Separation Feed Roller and Friction Belt Original Transport One flat belt Power Consumption 45 W Power Source 24 V 10 from the cop...

Page 617: ...pm A4 LT sideways 35 cpm A4 LT sideways Original Transport Speed 555 mm s 505 mm s Time Needed for Original Replacement A4 sideways 590 ms thin original mode 690 ms thick original mode 620 ms thin original mode 720 ms thick original mode DIFFERENCES FROM THE DF64 A548 ARDF A207 A211 A208 2 2 SM ...

Page 618: ...SECTION 3 20 BIN SORTER STAPLER ST30 A664 ...

Page 619: ...s A5 81 2 x 11 Lengthwise A5 51 2 x 81 2 Sideways A5 81 2 x 11 Lengthwise A5 51 2 x 81 2 B5 81 2 x 11 Maximum paper weight 157 g m2 42 lb 157 g m2 42 lb 157 g m2 42 lb Minimum paper weight 52 g m2 14 lb 52 g m2 14 lb 52 g m2 14 lb Maximum capacity All sizes 50 sheets bin Two sided copies 40 sheets bin All sizes 50 sheets bin Two sided copies 40 sheets bin All sizes 50 sheets 80 g m2 Stapling Posit...

Page 620: ...tridge Power Source DC24 V from copier Power Consumption Average less than 50 W Maximum In sort stack mode Less than 45 W In staple mode Less than 50 W Dimensions W x D x H 566 x 583 x 978 mm Weight Approximately 48 kg SPECIFICATIONS A207 A208 A211 3 2 SM ...

Page 621: ... Proof Transport Rollers 4 Turn Gate 5 Sorter Transport Rollers 6 Sorter Exit Rollers 7 Staple Unit 8 Grip Assembly 9 Helical Wheels 10 Jogger Plate 11 Bins 12 Upper Guide Plate 1 2 3 4 5 6 7 8 9 10 11 12 A664V501 wmf 20 Bin Sorter Stapler ST30 A664 COMPONENT LAYOUT SM 3 3 A207 A208 A211 ...

Page 622: ...ve Belt 7 Gripper Motor 8 Bin Drive Motor 9 Wheel Drive Belts 10 Grip Drive Belt 11 Jogger Motor 12 Staple Unit Drive Motor 13 Jogger Drive Belts 14 Bin Rear Plate Drive Motor 15 Sorter Exit Drive Belt 16 Sorter Exit Motor 1 2 3 4 5 6 7 8 9 10 12 13 14 15 9 5 13 16 13 11 A664V502 wmf COMPONENT LAYOUT A207 A208 A211 3 4 SM ...

Page 623: ... if there is paper in the bins 3 S2 Proof Exit Detects paper jams at the proof tray exit 4 S3 Entrance Detects paper jams at the entrance guides 5 S4 Staple Hammer Home Position Detects if the staple hammer is at the home position 10 S5 Stapler Unit Pulled out position Detects if the stapler unit is at the pulled out position 11 S6 Paper Detects whether copies are under the hammer 12 S7 Stapler Un...

Page 624: ...3 Grip Arm Positioning Moves the grip ass y to the rear and front to catch or release the paper to carry it to the stapler 15 PCBs PCB1 Main Control Controls all sorter stapler functions 29 Switches SW1 Door Safety Cuts the dc power when the front door is opened 6 SW2 Cartridge Set Detects if the staple cartridge is installed or not 7 SW3 Staple End Detects staple end 8 ELECTRICAL COMPONENT DESCRI...

Page 625: ...the mode Normal proof mode from the turn gate section to the proof tray The turn gate solenoid energizes to turn the turn gate clockwise when the key is pressed The turn gate directs copies through the proof transport section to the proof tray The main motor turns counterclockwise to rotate the vertical transport rollers B and proof exit roller C B A C A664D500 wmf 20 Bin Sorter Stapler ST30 A664 ...

Page 626: ...sorter transport section then the first copy is delivered between the top bin D and the upper guide plate E The jogger plate F then jogs to square the copies each time Before the next copy reaches the sorter exit roller the bin drive motor G rotates and advances the bin one step the helical wheels H rotate once When the cut out in the actuator reaches below the wheel sensor I the bin drive motor t...

Page 627: ... transport section then the copies are delivered between the top bin D and the upper guide plate E The jogger plate F then jogs to square the copies each time All copies of the copy run are then fed to the first bin When the final copy is delivered the wheel drive motor G turns and advances the bin one step the helical wheels H rotate once When the cut out in the actuator reaches below the wheel s...

Page 628: ...e paper The bin rear plate is turned so as to be flat with the sorter bin The grip assembly brings the copies down underneath the stapler Fig 2 The staple unit changes position the position varies depending on the copy size and staple mode and the stapler staples the copies Fig 3 Fig 1 A664D502 img Fig 2 A664D503 img Fig 3 A664D504 img BASIC OPERATION A207 A208 A211 3 10 SM ...

Page 629: ...t is returned to the home position There are two staple modes 1 Automatic stapling In ADF mode when staple mode is selected before pressing the key copies will be delivered to each bin and stapled automatically 2 Manual stapling In sort mode after copies are sorted in the bins the copies will be stapled when the manual staple key is pressed and the staple position is selected In stack mode manual ...

Page 630: ...ve belt E However the one way clutch in each sorter transport roller drive gear F does not transmit the drive to the sorter transport rollers In the sort stack and staple modes the turn gate solenoid stays off to direct copies downward to the sorter transport section When the key is pressed the main motor C turns counterclockwise In this mode main motor drive is not transmitted to the proof drive ...

Page 631: ...ockwise the bins lift black arrow and when it rotates counterclockwise the bins lower white arrow The wheel sensor actuator on the front helical wheel has a slot which detects when the helical wheel has rotated 360 degrees When the bins are advanced the helical wheels rotate once 360 degrees for each step As the pitch of the spiral on the helical wheel is greater when bins are at the staple and pa...

Page 632: ...t the home position When the main switch is turned on the bin lift motor E lowers the bins turns counterclockwise until the bottom bin actuates the bin home position sensor Then the bin lift motor raises the bins turns clockwise until the wheel sensor activates At this point the bins are in the home position B E A A664D511 wmf C D A664D512 wmf BIN HOME POSITION A207 A208 A211 3 14 SM ...

Page 633: ...me position to a point 10 mm wider than the selected paper 300 ms after the trailing edge of the copy passes underneath the bin jam sensor jam detection part the jogger motor rotates forward and in reverse This makes the jogger plate push all the copies against the front side plate to square the sheets When the jogger plate pushes the paper the plate shifts to a position 5 mm wider than the paper ...

Page 634: ...s constantly However when the sorter exit roller B rotates quickly the transport rollers also rotate quickly with the pulled paper because of the one way clutch in the drive gear E Jogger Off Conditions 1 Under the following conditions the jogger plate does not jog after copies are delivered to the bins If paper is loaded in a bin by hand while the sort stack or staple mode is selected If the sele...

Page 635: ...he stapling position by the grip assembly While the rear plate is down during stapling the bin rear plate open sensor H is interrupted by the actuator I bottom diagram After stapling is completed and stapled paper is returned to the bin gear C rotates 180 degrees and the bin rear plate returns to its home position When the bin rear plates are in the home position the bin rear plate HP sensor J is ...

Page 636: ...in this condition until the solenoid is energized by an opposite charge The inset at the upper right of the illustration shows the mechanical linkage as seen from the top The grip solenoid C activates to close the grip arms and the grip arms catch the papers For this solenoid also the plunger keeps the grip arms closed until the solenoid is energized by an opposite charge A B C A664D517 wmf OFF OF...

Page 637: ...grip arms to the home position to prepare for the next stapling cycle The grip home position sensor F is actuated while the gripper is in the home grip position The sorter stapler main control board sends the appropriate pulses to the grip motor a stepper motor A to reach the grip position and stapling position Vertical stapling positions can be adjusted by changing the number of stepper motor pul...

Page 638: ...ition and stays there until all stapling is completed It then returns to the home position In 2 Staples mode or Bottom single staple mode the stapling positions depend on the paper size The stapler unit drive motor B is a stepper motor and the stapling position is reached by counting the steps from the home position During stapling in the 2 Staples mode the stapler unit goes back and forth to stap...

Page 639: ...mmer home position sensor E is de actuated The stapler motor then stops When the paper sensor F in the grip assembly does not detect copies under the hammer the stapler motor does not rotate The staple end sensor G detects staple end conditions The cartridge set sensor H detects when the staple cartridge is not installed The staple cartridge has a clinch area J in which the jammed staples are left...

Page 640: ... If paper is loaded in a bin by hand while the staple mode is selected If only one sheet is delivered to the bin If the stack slip sheet or interrupt modes are selected 3 Under the following conditions the manual stapling mode in sort mode cannot be selected If paper is loaded in a bin by hand while the sort mode is selected If the paper size in the bin does not match the stapling specifications I...

Page 641: ...t pulled out position At this position the stopper arm B locks the stapler unit by dropping the arm to the edge of bracket C When the stapler unit is not pushed in completely the staple unit is between the stapler unit home position and stapler unit pulled out position D a message is displayed advising the user to put the staple unit in the home position B C D A A664D525 wmf 20 Bin Sorter Stapler ...

Page 642: ...fter the entrance sensor turns on J4 The proof exit sensor stays on for more than a certain number of pulses for example 280 pulses for A4 sideways In Sort Stack or Staple Mode J1 and J2 Same as Normal mode J5 The bin jam sensor has not turned on for 600 pulses after the entrance sensor turns on J6 The bin jam sensor stays on for more than a certain number of pulses for example 280 pulses for A4 s...

Page 643: ...PROOF MODE Copier Main Motor ON Proof mode Paper size data Exit signal Sorter busy S S exit signal S S main motor ON Entrance Sensor Proof Exit Sensor Timing Chart Signal A664D527 wmf 20 Bin Sorter Stapler ST30 A664 TIMING CHARTS SM 3 25 A207 A208 A211 ...

Page 644: ... Timing Chart Stapling Proof mode Staple mode Exit signal Paper size data Bin data Sorter busy S S Exit signal Proof count Job complete Entrance sensor Bin jam sensor Sorter exit motor Sorter main motor Jogger motor Stapler unit drive motor Grip motor Grip HP sensor Grip positioning solenoid Grip solenoid Stapler motor Bin rear plate drive motor Bin drive motor NOTE 1 NOTE 1 NOTE 2 NOTE 3 300 ms A...

Page 645: ...0 0 5 mm 1 0 0 0 1 1 0 mm 0 1 0 0 1 1 5 mm 1 1 0 0 1 2 0 mm 0 0 1 0 1 2 5 mm 1 0 1 0 1 3 0 mm 0 1 1 0 1 3 5 mm 1 1 1 0 1 direction See the illustration below 0 direction See the illustration below 1 NOTE The adjustment value and the combination of the dip switch positions are exactly the same for Dip Switch 101 and Dip Switch 102 direction Feed direction direction direction Feed direction directio...

Page 646: ...14 2 TEST POINTS Number Function TP100 GND TP101 5 V 14 3 FUSES FUSES Rated Current and Voltage FUSE100 250 V T5A SERVICE TABLES MAIN CONTROL BOARD A207 A208 A211 3 28 SM ...

Page 647: ... B 3 screws 4 Remove the front wheel cover C 3 screws 5 Remove the four screws that hold the front left cover D and remove the front left cover by shifting the cover up to release the two hooks 6 Remove the front lower cover E 3 screws 7 Remove the front door F 2 hinge pins C B A A664R500 wmf E F D A664R501 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJUSTMENT SM 3 29 A207 A208 A211 ...

Page 648: ... Rear 1 Remove the rear cover A 6 screws 2 Remove the bottom plate B 2 screws and 1 hook A B A664R502 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 30 SM ...

Page 649: ...l out the R3 release lever B and pull out the stapler unit 3 Remove the harness cover C 4 Remove the stapler unit D 1 connector and 1 screw NOTE When re assembling hook the cut out E over the shoulder screw F A B A664R503 wmf C D F E A664R504 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJUSTMENT SM 3 31 A207 A208 A211 ...

Page 650: ...er B then pull out the jogger plate C Installation 1 Insert the jogger plate through the upper holder B 2 Push down the jogger plate towards the lower holder D 3 Set the jogger plate in the lower holder D 4 Hook the spring A of the upper jogger holder onto the stopper E A B C E A664R505 wmf D A664R506 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 32 SM ...

Page 651: ...oval then move the upper jogger holder A to the front 4 Remove the rear cover then remove the bottom plate to access the drive belt Refer to Exterior Cover Removal 5 Manually rotate the helical wheel drive belt B and move up the top guide C until the three guide pins D reach the top of the helical wheel as shown A A664R507 wmf B C D A664R508 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJU...

Page 652: ... and F from cut outs G and H 7 Move up the next bin to the top position by manually rotating the helical wheel drive belt and remove it as in the top guide removal procedure steps 5 and 6 8 Remove the other nineteen bins by repeating step 7 A B C D A664R509 wmf E F G H A664R510 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 34 SM ...

Page 653: ...ear guide pin to the corner D 2 While still holding the bin rear plate straight insert the front right guide pin E into guide slot F 3 Insert the other guide pins G and H into the slots I and J A E G H C F A664R511 wmf J E D I B A664R512 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJUSTMENT SM 3 35 A207 A208 A211 ...

Page 654: ...helical wheels only once Otherwise the distance between the guide pins B will become uneven and the bins will tilt 5 Install all bins and the top cover by repeating steps 1 to 4 6 Re install the jogger plate and all covers A A664R513 wmf B Good No good A664R514 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 36 SM ...

Page 655: ... 1 Remove the rear cover 4 screws 2 Disconnect the connector A 3 Remove the main motor bracket B 4 screws with the main motor A B A664R515 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJUSTMENT SM 3 37 A207 A208 A211 ...

Page 656: ...below Grip solenoid B and the grip arm positioning solenoid C adjustments It is impossible to perform the fine positioning adjustments for these solenoids because the magnets in both solenoids pull the plunger very strongly So mark the original position of the solenoids before removing the solenoid Then place the solenoid at the original position by referring to the mark you made D and tighten the...

Page 657: ...oard and connect all connectors 4 Position DIP SW 100 101 and 102 as on the original main control board DIP SW 101 and 102 are for stapling position adjustment and DIP SW 100 is for SP mode 5 Turn on the copier main switch then check the stapling position If it is incorrect adjust the stapling position Refer to the Stapling Position Adjustment A A664R520 wmf 20 Bin Sorter Stapler ST30 A664 REPLACE...

Page 658: ...15 8 GRIP MOTOR REMOVAL 1 Remove the grip assembly 2 Remove the grip motor A 4 screws and 2 Allen screws A A664R519 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 40 SM ...

Page 659: ... Wheel 1 Remove the bracket A 4 screws 2 Remove the wheel sensor bracket B 1 screw 3 Unhook the two springs C 4 Loosen the two Allen screws D 5 While holding the pulley E to keep it in position remove the helical wheel F A A664R524 wmf B F A664R525 wmf C C D D E A664R526 wmf 20 Bin Sorter Stapler ST30 A664 REPLACEMENT AND ADJUSTMENT SM 3 41 A207 A208 A211 ...

Page 660: ...e bracket A 3 screws 2 Loosen the two Allen screws B on the drive pulley 3 While holding the pulley C to keep it in position remove the helical wheel D A D A664R527 wmf C D B A664R528 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 3 42 SM ...

Page 661: ... the helical wheel on the bearing A 3 Place the bracket with the bushing D on top of the helical wheel then install and slightly tighten three screws E 4 Place a 0 4 mm thickness gauge F between the helical wheel B and the bushing D on the bracket While holding the bushing down on the helical wheel tighten the three screws E B C A A664R533 wmf D E F B 0 4 mm A664R534 wmf 20 Bin Sorter Stapler ST30...

Page 662: ...al wheel H in the pulley E Leave the Allen screws I loosened 5 Place the bracket with a bushing J on top of the helical wheel then install and slightly tighten the four screws K 6 Place a 0 4 mm thickness gauge L between the helical wheel and the bushing on the bracket While holding the bushing down on the helical wheel H tighten the four screws K 7 Hook tension springs M and N then tighten the sc...

Page 663: ...2 Allen screws on each drive pulley 4 In this condition place the cut out D on the wheel sensor actuator under the wheel sensor E then tighten the Allen screw on the wheel sensor actuator 5 Make sure that the gaps F and G between the base plates and the pulleys are as shown in the illustration C B A C A664R538 wmf D E A664R539 img G F G 22 5 0 5 mm F 1 7 0 5 mm Front Rear A664R540 wmf 20 Bin Sorte...

Page 664: ...SECTION 4 20 BIN SORTER STAPLER ST29 A658 ...

Page 665: ...opies Stapler Capacity 2 20 copies Proof Tray Capacity 100 sheets 80g m2 20 lb Number of Bins 20 bins proof tray Stapling Position a 6 3 mm b 6 3 mm Staple Replenishment Cartridge exchange 2 000 staples cartridge Power Source DC 24 V from the copier Power Consumption Average less than 35 W Average for Sorting less than 30 W Average for Stapling less than 33 W Weight 20 5 kg 27 4 lb Dimensions W x ...

Page 666: ...ENT LAYOUT 2 1 MECHANICAL COMPONENT LAYOUT 7 1 2 3 4 5 6 A658V501 wmf 1 Helical Wheels 2 Jogger Plate 3 Grip Assembly 4 Transport Rollers 5 Staple Unit 6 Bins 7 Proof Tray COMPONENT LAYOUT A207 A208 A211 4 2 SM ...

Page 667: ... 8 5 A658V502 wmf 1 Jogger Drive Belt 2 Transport Roller 3 Wheel Drive Belts 4 Helical Wheels 5 Transport Motor 6 Bin Drive Motor 7 Jogger Motor 8 Jogger Plate 20 Bin Sorter Stapler ST29 A658 COMPONENT LAYOUT SM 4 3 A207 A208 A211 ...

Page 668: ... the grip assembly cam gear has rotated once 6 S3 Bin Home Position Detects whether the bins are at home position 11 S4 Sorter Entrance Detects paper jams 2 S5 Jogger Home Position Detects whether the jogger plate is in its home position 13 S6 Wheel Detects the bin position 12 S7 Bin LED Detects whether there is paper in the bins light emitting element 10 S8 Stapler Paper Detects whether any copie...

Page 669: ...ansport rollers C The transport rollers send copies to the proof tray directly Sort mode When sort mode is selected the bin drive motor D energizes to rotate the helical wheels The helical wheels E rotate twice to move the top bin to the transport roller position then the first copy is delivered to the top bin After the first copy of the first original has been fed to the top bin the bin drive mot...

Page 670: ...ck mode is selected the top bin advances to the transport roller position in the same way as in sort mode After the first copy is delivered to the top bin the jogger plate A moves across to square the copy The jogger plate squares the copies after each copy has been fed to a bin After one set of copies for the first original has been delivered to the top bin the bin drive motor moves the bins up o...

Page 671: ...escends one step D depending on whether the page is an odd or even numbered page of the original When the final set of copies has been stapled the bins go back to the standby position There are two staple modes Automatic Stapling In ADF mode when staple mode is selected before pressing the key copies will be delivered to each bin and stapled automatically Manual Stapling In platen cover mode after...

Page 672: ...he motor rotates clockwise the bins lift when it rotates counterclockwise the bins lower There is a wheel sensor D located under the actuator E on the rear helical wheel the actuator has a slot which detects when the helical wheel has rotated once When the bins are advanced the helical wheels rotate once for each step As the pitch of the spiral on the helical wheel is greater when the bins are at ...

Page 673: ... When the main switch is turned on the sorter stapler initializes itself to check whether the component parts work or not At this time the bin drive motor raises the bins for a few moments then it lowers the bins until the bottom bin actuates the bin home position sensor A A658D505 wmf 20 Bin Sorter Stapler ST29 A658 BASIC OPERATION SM 4 9 A207 A208 A211 ...

Page 674: ... moves three times to square the stack of paper First when the paper has been fed completely into the bin at the proper time after the copy has passed through the entrance sensor E depending on the paper length the jogger motor moves the jogger plate out of the jogger home position Then the jogger motor drives the jogger plate to the width of the copy Finally the jogger plate moves inward to push ...

Page 675: ...tates counterclockwise once so that the stapled copies go back to the bin and the cam gear returns to its home position When the cam pushes the roller G on the lever H and the lever pushes the grip arm the grip arm can catch the copies A pin I on the cam gear fits into the slot in the grip arm unit So when the cam gear rotates the slot moves the grip arm unit inward and outward The actuator J on t...

Page 676: ...position sensor F is deactuated and the stapler motor stops When the stapler paper sensor G in the grip assembly does not detect any copies under the hammer the stapler motor does not rotate When the trailing edge of the last staple sheet pass through the staple end sensor H the sorter stapler enters the staple near end condition After the current job is completed the Add Staples indicator lights ...

Page 677: ...tions staple mode is disabled If there is paper in a bin before the main switch is turned on If the selected paper size does not match the stapling specifications If the paper is fed from the by pass feed table If the stack or interrupt modes are selected 2 Under the following conditions staple mode is canceled if it had been selected If paper is inserted into a bin by hand while the staple mode i...

Page 678: ...n drive and the jogger motors depend on the paper size as shown in the following table 2 Bin No Paper Size Bin drive motor timing Jogger motor timing Paper Size Bin drive motor timing Jogger motor timing A3 11 x17 80 ms 270 ms A4 lengthwise 81 2 x11 254 ms 96 ms B4 160 ms 190 ms B5 sideways 160 ms 190 ms A4 sideways 11 x81 2 80 ms 270 ms B5 lengthwise 310 ms 40 ms A658D512 wmf A658D513 wmf BASIC O...

Page 679: ... Staple Mode A4 sideways two copies of a two page original after sorting 150 mm s A658D514 wmf 20 Bin Sorter Stapler ST29 A658 BASIC OPERATION SM 4 15 A207 A208 A211 ...

Page 680: ...orter entrance sensor does not turn off within 1 s after the fusing exit sensor has turned off Staple Jam In the following conditions a staple jam will occur and the sorter jam indicator on the operation panel will light 1 If the stapler paper sensor is on when the main switch turns on or just as the stapler cover is closed 2 If the stapler paper sensor stays on after the stapling job has been fin...

Page 681: ...ear cover B 3 screws 4 1 3 Top Cover 1 Remove the rear cover B 2 Remove the top cover support bracket C 1 screw 3 Remove the top cover C 1 screw 4 1 4 Lower Cover 1 Remove the front cover A and the rear cover B 2 Remove the lower cover E D A E B C A658R506 wmf 20 Bin Sorter Stapler ST29 A658 REPLACEMENT AND ADJUSTMENT SM 4 17 A207 A208 A211 ...

Page 682: ...NIT REMOVAL 1 Remove the front cover See Exterior Cover Removal 2 Loosen the screws A 3 Remove the staple unit B as shown 1 screw and 1 connector B A A A658R500 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 4 18 SM ...

Page 683: ...s 2 connectors and 1 grounding wire 3 Remove the spring B and remove the slider C 4 Remove the grip arm unit D 1 screw and 1 clip 5 Remove the grip arm plate E 2 screws 6 Replace the grip arms F A A658R501 wmf B C D F E A658R502 wmf 20 Bin Sorter Stapler ST29 A658 REPLACEMENT AND ADJUSTMENT SM 4 19 A207 A208 A211 ...

Page 684: ... upper stay bracket A 4 screws and 1 connector 3 Loosen the two screws B then remove the timing belt C 4 Remove the brackets D 3 springs each 5 While moving the helical wheels E outward remove the bins F C A B A658R503 wmf D E D E F A658R504 wmf REPLACEMENT AND ADJUSTMENT A207 A208 A211 4 20 SM ...

Page 685: ...he sorter stapler 1 screw and 1 chain 2 Remove the rear cover See Exterior Cover Removal 3 Remove the transport motor A 2 screws and 4 washers A A658R505 wmf 20 Bin Sorter Stapler ST29 A658 REPLACEMENT AND ADJUSTMENT SM 4 21 A207 A208 A211 ...

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