Page 1 CÓPIA NÃO CONTROLADA A156/A212...SERIES SERVICE MANUAL PN: RCFM5535 RICOH GROUP COMPANIES CÓPIA NÃO CONTROLADA...
Page 2 CÓPIA NÃO CONTROLADA RICOH GROUP COMPANIES CÓPIA NÃO CONTROLADA...
Page 3 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 4 CÓPIA NÃO CONTROLADA Rev. 4/98 A156/A153 A160/A157 A162/A161 FIELD SERVICE MANUAL PN:RCFM5535 CÓPIA NÃO CONTROLADA...
Page 5 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 6 CÓPIA NÃO CONTROLADA It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION.
Page 7 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 8 CÓPIA NÃO CONTROLADA Rev. 4/98 LEGEND PRODUCT CODE COMPANY GESTETNER RICOH SAVIN A156 2635TD FT5535 9035DL A153 2635 FT5035 9035 A160 2627TD FT4527 9027DL A157 2627 FT4027 9027 A162 2822TD FT4522 9220DL A161 2822 FT4022 9220 A207 2740TD FT5840 9400D...
Page 9 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 10 The Field Service Manual contains information r egarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.
Page 11 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 12: Table Of Contents
CÓPIA NÃO CONTROLADA Table of Contents 1. OVERALL MACHINE INFORMATION 1. SPECIFICATIONS..............1-1 2. COMPONENT LAYOUT AND DESCRIPTION 1. MACHINE CONFIGURATION..........2-1 1.1 COPIER ..................2-1 1.2 OPTIONAL EQUIPMENT .............2-2 2. MECHANICAL COMPONENT LAYOUT ......2-3 3. PAPER PATH ..............2-6 3.1 NORMAL COPYING..............2-6 3.2 DUPLEX COPYING ..............2-7 4.
Page 13 CÓPIA NÃO CONTROLADA 2.3.3 Paper Size Selection for the Paper Tray Unit, LCT, and By-pass Feed ...... 3-15 ...... 2.3.4 Special Paper Size Selection for the 1st Tray ........3-16 2.4 SORTER ADAPTER INSTALLATION (OPTION FOR A157, A159, AND A160 COPIERS ONLY) ........3-17 2.4.1 Accessory Check ..................
Page 14 CÓPIA NÃO CONTROLADA Rev. 7/95 2.2 MEMORY RESET PROCEDURES ..........4-9 2.2.1 Resetting Counters................... 4-9 2.2.2 Reset All Counters: SP7-808..............4-10 2.2.3 Drum Initialization: SP3-123..............4-11 2.2.4 Reset All Memory (SP5-801) ..............4-12 2.3 SERVICE PROGRAM MODE TABLE ........4-14 2.3.1 Quick Reference..................4-14 2.3.2 SP Mode Table ..................
Page 15 CÓPIA NÃO CONTROLADA Rev. 7/95 1.1.4 Front Right Cover ..................5-2 1.1.5 Rear Right Cover..................5-2 1.1.6 Top Cover ....................5-2 1.1.7 Operation Panel ..................5-2 1.2 INNER COVER REMOVAL ............5-3 1.2.1 Upper Inner Cover ..................5-3 1.2.2 Lower Right Inner Cover ................5-3 1.2.3 Lower Left Inner Cover................
Page 16 CÓPIA NÃO CONTROLADA Rev. 7/95 5. TRANSFER BELT UNIT ..........5-29 5.1 TRANSFER BELT UNIT REPLACEMENT .........5-29 5.2 TRANSFER BELT REPLACEMENT ........5-30 5.3 TRANSFER BELT CLEANING BLADE REPLACEMENT .................5-31 5.4 DISPOSING OF COLLECTED TONER ........5-32 6. PAPER FEED ..............5-33 6.1 BY-PASS PICK-UP, FEED, AND SEPARATION ROLLERS, AND TORQUE LIMITER REPLACEMENT........5-33 6.2 PICK-UP, FEED, AND SEPARATION ROLLERS,...
Page 17 CÓPIA NÃO CONTROLADA Rev. 7/95 8.6 THERMOFUSE REPLACEMENT ..........5-46 9. DUPLEX UNIT ..............5-47 9.1 FRICTION ROLLER REPLACEMENT ........5-47 9.2 DUPLEX FEED ROLLER REPLACEMENT .......5-48 9.3 DUPLEX FEED MOTOR REPLACEMENT ......5-49 10. COPY QUALITY ADJUSTMENT ........5-51 10.1 LIGHT INTENSITY ADJUSTMENT (SP4-001) ......5-51 10.2 UNEVEN EXPOSURE ADJUSTMENT ........5-53 10.3 IMAGE AREA BIAS VOLTAGE ADJUSTMENT ......5-54 10.3.1 Development Bias Adjustment (SP2-201-001) ........
Page 18 CÓPIA NÃO CONTROLADA Rev. 7/95 11. OTHERS ................5-66 11.1 MAIN CONTROL BOARD REPLACEMENT ......5-66 11.2 AC POWER SUPPLY BOARD REPLACEMENT .....5-67 11.3 DC POWER SUPPLY BOARD REPLACEMENT .....5-68 11.4 CB HIGH VOLTAGE SUPPLY BOARD REPLACEMENT ..5-69 11.5 T HIGH VOLTAGE SUPPLY BOARD REPLACEMENT ..5-70 6.
Page 19 CÓPIA NÃO CONTROLADA Rev. 7/95 3.1 SUMMARY...................6-26 3.2 SC CODE TABLE................6-26 3.3 WARNING SC CODE TABLE .............6-28 3.4 C-CODE TABLE ................6-29 3.5 U-CODE TABLE ................6-29 3.6 SC CODE DESCRIPTIONS............6-30 4. BLOWN FUSE CONDITIONS ..........6-43 5. ELECTRICAL COMPONENT DEFECTS......6-44 5.1 SENSORS..................6-44 5.2 SWITCHES ..................6-47 APPENDIX...
Page 20 CÓPIA NÃO CONTROLADA Rev. 7/95 6. REPLACEMENT AND ADJUSTMENT ......7-9 6.1 TRANSPORT BELT REPLACEMENT..........7-9 6.2 FEED ROLLER REPLACEMENT ..........7-10 6.3 FRICTION BELT REPLACEMENT ..........7-11 6.4 ORIGINAL SET AND ORIGINAL WIDTH SENSOR REPLACEMENT ............7-12 6.5 VERTICAL REGISTRATION ADJUSTMENT ......7-13 6.5.1 One Sided Thin Original Mode............... 7-13 6.5.2 Two Sided Original Mode ..............
Page 21 CÓPIA NÃO CONTROLADA Rev. 7/95 5.5 RELAY SENSOR REPLACEMENT ..........8-15 9. PAPER TRAY UNIT A553 1. SPECIFICATIONS..............9-1 2. COMPONENT LAYOUT............9-2 2.1 MECHANICAL COMPONENT LAYOUT ........9-2 2.2 DRIVE LAYOUT ................9-2 2.3 ELECTRICAL COMPONENT DESCRIPTION ......9-3 3. INSTALLATION..............9-4 3.1 ACCESSORY CHECK ..............9-4 3.2 INSTALLATION PROCEDURE.............9-5 3.3 TRAY HEATER (OPTION) ............9-7 4.
Page 22 CÓPIA NÃO CONTROLADA Rev. 7/95 5. SERVICE TABLES (MAIN BOARD)........ 10-14 5.1 DIP SWITCHES .................10-14 5.2 LED AND VARIABLE RESISTOR ..........10-14 5.3 TEST POINTS................10-14 6. REPLACEMENT AND ADJUSTMENT......10-15 6.1 STAPLER REMOVAL ...............10-15 6.2 GRIP ASSEMBLY REMOVAL ..........10-16 6.3 BIN REPLACEMENT ..............10-17 6.4 BIN LIFT WIRE REPLACEMENT ..........10-20 6.4.1 Wire Removal ..................
Page 23 CÓPIA NÃO CONTROLADA Rev. 7/95 4. SERVICE TABLES............11-11 4.1 DIP SWITCHES .................11-11 4.2 TEST POINTS................11-12 4.3 LED ....................11-12 4.4 VARIABLE RESISTOR .............11-12 5. REPLACEMENT AND ADJUSTMENT ......11-13 5.1 EXTERIOR COVER REMOVAL..........11-13 5.2 STAPLE UNIT REMOVAL ............11-13 5.3 GRIP ARM REPLACEMENT ...........11-14 5.4 BIN REPLACEMENT .............11-15 5.5 TRANSPORT MOTOR REPLACEMENT .......11-16...
Page 24 CÓPIA NÃO CONTROLADA Rev. 7/95 3. ELECTRICAL COMPONENT DESCRIPTIONS ....13-3 4. INSTALLATION ..............13-4 4.1 ACCESSORY CHECK ..............13-4 4.2 INSTALLATION PROCEDURE...........13-5 5. PREPARATION FOR TRANSPORTATION ...... 13-8 6. ROLLER DRIVE BELT REPLACEMENT ......13-9 7. BIN GUIDE LUBRICATION ..........13-10 BULLETINS xiii A156/A160/A162...
Page 25 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 26 CÓPIA NÃO CONTROLADA TAB INDEX Rev. 1/98 OVERALL MACHINE INFORMATION PAPER TRAY UNIT A553 A207 OVERALL MACHINE INFORMATION COMPONENT LAYOUT AND DESCRIPTION SORTER STAPLERA554 DOCUMENT FEEDER A663 INSTALLATION SORTER STAPLER A555 SORTER STAPLER A664 SERVICE TABLES SORTER A556 SORTER STAPLER A658 REPLACEMENT AND ADJUSTMENT SORTER A557 A212/A214 SERVICE MANUAL...
Page 27 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 28 2. The RAM board has a lithium battery which can explode if handled incorrectly. Replace only with the same type of RAM board. Do not recharge or burn this battery. Used RAM boards must be handled in accordance with local regulations. FT5535/4527/4522 CÓPIA NÃO CONTROLADA...
Page 29 100 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. FT5535/4527/4522 CÓPIA NÃO CONTROLADA...
Page 30: Overall Machine Information
CÓPIA NÃO CONTROLADA OVERALL MACHINE INFORMATION CÓPIA NÃO CONTROLADA...
Page 31 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 32: Specifications
CÓPIA NÃO CONTROLADA Rev. 7/95 1. SPECIFICATIONS Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum A3/11" x 17" Copy Paper Size: Maximum A3/11" x17" (Paper trays) Minimum A5/8 " x 5 " sideways (Paper trays) A4/11"...
Page 33 CÓPIA NÃO CONTROLADA Rev. 7/95 Power Consumption: A153, and A156 copiers A157, and A160 copiers Copier Only Full System Copier Only Full System Maximum 1.45 KW 1.50 KW 1.45 KW 1.50 KW Copying 1.00 KW 1.00 KW 0.80 KW 0.80 KW Warm-up 0.90 KW 0.92 KW...
Page 34 2) With platen cover and copy tray attached 3) With LCT cover closed Weight: Weight FT5035 A153 copier About 70 kg (154.2 lb) FT5535 A156 copier About 82 kg (180.7 lb) FT4027 A157 copier About 67 kg (147.7 lb) FT4527 A160 copier About 80 kg (176.4 lb) FT4022 A161 copier About 67 kg (147.7 lb)
Page 35 CÓPIA NÃO CONTROLADA Rev. 7/95 Copy Number Input: Ten-key pad, 1 to 999 (count up or count down) Manual Image Density 7 steps Selection: Automatic Reset: 1 minute is the standard setting; it can be changed to a maximum of 999 seconds or no auto reset by SP mode.
Page 36: Component Layout And Description
CÓPIA NÃO CONTROLADA COMPONENT LAYOUT AND DESCRIPTION CÓPIA NÃO CONTROLADA...
Page 37 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 38: Machine Configuration
CÓPIA NÃO CONTROLADA Rev. 7/95 1. MACHINE CONFIGURATION 1.1 COPIER A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 39: Optional Equipment
CÓPIA NÃO CONTROLADA Rev. 7/95 1.2 OPTIONAL EQUIPMENT * Only available on models FT5535 and FT4527 ** Not for use on FT4022/4522(A161/A163) copiers. A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 40: Mechanical Component Layout
CÓPIA NÃO CONTROLADA 2. MECHANICAL COMPONENT LAYOUT – A156 copier – 27 26 25 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.
Page 41 CÓPIA NÃO CONTROLADA Rev. 7/95 – A160/A162 copier – 28 27 26 25 NOTE: The A157/A161 copiers are the same as the A160/A162 copiers except that the A157and A161 do not have a duplex tray or an LCT. A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 42 CÓPIA NÃO CONTROLADA Rev. 7/95 1. 3rd Mirror 22. Vertical Transport Rollers 2. 2nd Mirror 23. Paper Feed Roller The roller for A153/A156 3. 1st Mirror copiers is different from that for A157/160/161/162 copiers. 4. Exposure Lamp 24. Friction Pad 5.
Page 43: Paper Path
CÓPIA NÃO CONTROLADA Rev. 7/95 3. PAPER PATH 3.1 NORMAL COPYING – A156 copier – –A160/A162 copier – A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 44: Duplex Copying
CÓPIA NÃO CONTROLADA Rev. 7/95 3.2 DUPLEX COPYING – A156 copier – – A160/A162 copier – A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 45 CÓPIA NÃO CONTROLADA 4. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout and the point to point diagram on the waterproof paper in the pocket for symbols and index numbers. Index Symbol Description Note Printed Circuit Boards Main Control Controls all copier functions both directly or PCB1 through other control boards.
Page 46 CÓPIA NÃO CONTROLADA Rev. 7/95 Index Symbol Description Note Side Fence Jogger Drives the side fence jogger to square the (Duplex machines paper stack. only) Sensors By-pass Feed Paper Informs the CPU what width paper is in the Width by-pass feed table. By-pass Feed Paper Informs the CPU that there is no paper in the by-pass tray.
Page 47 CÓPIA NÃO CONTROLADA Rev. 7/95 Index Symbol Description Note Auto Response (Not Returns the operation panel display and used on A161/A162 exits from the energy saver mode. copiers Transfer Belt Contact Informs the CPU of the current position of both the transfer belt unit and the drum charge roller unit.
Page 48 CÓPIA NÃO CONTROLADA Index Symbol Description Note Magnetic Clutches Toner Supply Turns the toner supply roller to supply toner to the development unit. Development Drives the development roller. Transfer Belt Contact Controls the touch and release movement of (1/3 Turn Clutch) both the transfer belt unit and the drum charge roller unit.
Page 49 CÓPIA NÃO CONTROLADA Index Symbol Description Note Heaters Drum Turns on when the main switch is off to keep the temperature around the drum charge roller at a certain level. Also prevents moisture from forming around the drum. Optics Turns on when the main switch is off to Anti-condensation prevent moisture from forming on the optics.
Page 50: Drive Layout
CÓPIA NÃO CONTROLADA 5. DRIVE LAYOUT 5.1 ALL MODELS 1. Drum Drive Pulley 8. Main Motor 2. Drum Charge Roller Drive Gear 9. Main Pulley 3. Transfer Belt Contact Clutch 10. Registration Clutch Gear Gear 11. By-pass Feed Clutch Gear 4.
Page 51: A153/A156
CÓPIA NÃO CONTROLADA Rev. 7/95 5.2 A153/A156 1. Upper Paper Feed Clutch 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.
Page 52: Installation
CÓPIA NÃO CONTROLADA INSTALLATION CÓPIA NÃO CONTROLADA...
Page 53 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 54: Installation Requirements
CÓPIA NÃO CONTROLADA Rev. 7/95 1. INSTALLATION REQUIREMENTS 1.1 ENVIRONMENT 1. Temperature Range: 10°C to 30°C (50°F to 86°F) 2. Humidity Range: 15% to 90% RH 3. Ambient Illumination: Less than 1,500 lux (do not expose to direct sunlight.) 4. Ventilation: Room air should turn over at least 3 /hr/person 5.
Page 55: Minimum Space Requirements
CÓPIA NÃO CONTROLADA 1.3 MINIMUM SPACE REQUIREMENTS Place the copier near the power source, providing clearance as shown: More than 10 cm/4.0" REAR More than More than 28.5 cm/11.3" (See Note *2) 39 cm/15.4" (See Note *1) Your machine FRONT More than 70 cm/27.6"...
Page 56: Power Requirements
CÓPIA NÃO CONTROLADA 1.4 POWER REQUIREMENTS CAUTION A. Be sure to ground the machine. B. Make sure the plug is firmly inserted in the outlet. C. Avoid multi-wiring. 1. Input voltage level: 120V/60Hz: More than 12 A (for North America) 220V~240V/50Hz: More than 7 A (for Europe) 220V/50Hz:...
Page 57: Copier Installation
CÓPIA NÃO CONTROLADA 2. COPIER INSTALLATION 2.1 ACCESSORY CHECK Check the quantity and condition of the accessories in the box against the following list: Description 1. Paper Size Decal ..................1 2. Symbol Explanation Decal (except for the A156 copier) ......1 3.
Page 58: Copier Installation Procedure
CÓPIA NÃO CONTROLADA Rev. 7/95 2.2 COPIER INSTALLATION PROCEDURE - A153/A155/A156 copiers - - A157/A159/A160 copiers - - A155/A156/A159/A160 copiers - CAUTION Never lift the machine by holding the LCT, or the LCT will break. NOTE: (1) Keep the shipping retainers after installing the machine. They will be reused if the machine is moved to another location in the future.
Page 59 CÓPIA NÃO CONTROLADA - A156 copier - - A160 copier - 4. A156/A160 copiers only: 1) Pull out the duplex tray [A] and remove the strips of tape [B]. 2) Remove the guide roller stopper [C] and a sheet of paper [D]. 3) Open the upper duplex guide plate [E] and remove the strips of tape [F].
Page 60 CÓPIA NÃO CONTROLADA - A153/A155/A156 copiers - - A157/A159/A160 copiers - 5. Open the front cover and swing out the toner bottle holder [A]. 6. Remove the strips of tape [B]. 7. Remove the switch actuator lock bracket [C] as shown. 8.
Page 61 CÓPIA NÃO CONTROLADA Rev. 7/95 11. Remove the knob screw [A]. Swing out the bottle holder [B] and pull down the lock lever [C]. Then slide out the bottle holder assembly [D] and swing out the bottle holder assembly [D]. 13.
Page 62 CÓPIA NÃO CONTROLADA 15. Disconnect the connector [A] and separate the toner supply unit [B] from the development unit (2 screws). 16. Pour about half a pack of developer [C] into the development unit. Then rotate the outer gear [D] as shown to distribute the developer evenly. Then pour in all the remaining developer and rotate the gear again.
Page 63 CÓPIA NÃO CONTROLADA Rev. 7/95 19. Swing in the bottle holder assembly [A] so that the toner bottle holder [B] and the slide rail [C] are aligned straight. IMPORTANT: Do not swing the bottle holder into the machine before doing step 20. 20.
Page 64 CÓPIA NÃO CONTROLADA Rev. 7/95 24. Enter SP mode as follows: 1) Press the "Clear Modes" key. 2) Enter "107" using the numeric keys. 3) Hold down the "Clear/Stop" key for more than 3 seconds. NOTE: 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.
Page 65 CÓPIA NÃO CONTROLADA On the paper tray On the duplex tray 28. Pull out the paper tray and load paper into it. (The paper size and direction for each tray should be as specified by the customer.) NOTE: The side and rear fences should be properly positioned. 29.
Page 66: Paper Size Selection
CÓPIA NÃO CONTROLADA Rev. 08/2001 2.3 PAPER SIZE SELECTION 2.3.1 Paper Feed Station Definition ⇒ A155 and A159 A153/A157/A161 A206 and A210 A204/A208/A212 By-pass Feed By-pass Feed Copier Copier 1st tray 1st tray 2nd tray 2nd tray 3rd tray 3rd tray 4th tray Paper Tray Unit 4th tray...
Page 67: Paper Size Selection For Copier Paper Trays
CÓPIA NÃO CONTROLADA Rev. 08/2001 2.3.2 Paper Size Selection for Copier Paper Trays ⇒ For the 1st tray and 2nd tray for A153, A155, A157, A159, A161 and A204, A206, A208, A210 and A212 copiers, and the 1st tray for A156, A160, A162 and A207, A211 and A214 copiers, slide the paper size slider [A] to the paper size indication that matches the paper size in the tray.
Page 68 CÓPIA NÃO CONTROLADA Rev. 08/2001 2.3.3 Paper Size Selection for the Paper Tray Unit, LCT, and By-pass Feed For the paper tray unit, LCT and by-pass feed, select the paper size with SP mode (SP5-019) using the following procedure. 1. Enter SP mode as follows; 1) Press the "Clear Modes"...
Page 69: Special Paper Size Selection For The 1St Tray
CÓPIA NÃO CONTROLADA Rev. 08/2001 4. Select the required SP setting with the numeric keys (see Service Tables - Paper Size Settings), then press the "Enter" key. NOTE: If you input the wrong setting by mistake, you can cancel it by pressing the "Clear/Stop"...
Page 70: Sorter Adapter Installation (Option For A157, A159, And A160 Copiers Only)
CÓPIA NÃO CONTROLADA 2.4 SORTER ADAPTER INSTALLATION (OPTION FOR A157, A159, AND A160 COPIERS ONLY) 2.4.1 Accessory Check Check the quantity and condition of the accessories in the box against the following list. Description 1. Installation Procedure ................1 2. Sorter Adapter Front Cover..............1 3.
Page 71: Installation Procedure
CÓPIA NÃO CONTROLADA 2.4.2 Installation Procedure 1. Remove the cover plate [A] (2 screws). 2. Remove the three plastic caps [B] from the copier left cover with nippers. 3. Install the sorter adapter [C] (4 tapping screws) in the paper exit section of the copier.
Page 72: Tray Heater Installation (Option)
CÓPIA NÃO CONTROLADA Rev. 7/95 2.5 TRAY HEATER INSTALLATION (OPTION) NOTE: The optional tray heater keeps copy paper dry. In humid environments, copy paper may crease as it comes out of the fusing unit. The heater is available as a service part. (See the parts catalog.) CAUTION Unplug the copier power cord before starting the following procedure.
Page 73 CÓPIA NÃO CONTROLADA Rev. 7/95 4. Remove the rear cover. (See "Replacement and Adjustment - Inner and Outer Covers".) 5. Pull out the carrying handles [A]. 6. Before installing the heater, bind the heater harness [B] with insulating tape [C] as shown to prevent the heater harness from being damaged by the edge of the copier main frame.
Page 74: Optics Anti-Condensation Heater (Option)
CÓPIA NÃO CONTROLADA Rev. 7/95 2.6 OPTICS ANTI-CONDENSATION HEATER (OPTION) NOTE: The optics anti-condensation heater keeps water from condensing on the copier’s mirrors. Such condensation occurs at cold temperatures with high humidity, and causes the first few copies of the day to be dark, or even black. The heater is available as a service part.
Page 75 CÓPIA NÃO CONTROLADA 7. Connect the red two-pin connector [F] at the rear of the copier to the heater’s connector [C] (red). 8. Place the harness [G] under the optical rail [H] as shown. 9. Make sure that the scanner drive belt and mirrors do not touch the heater harness while they are functioning.
Page 76: Original Length Sensor For Aps (Option Only For The Lt/Dlt Version)
CÓPIA NÃO CONTROLADA 2.7 ORIGINAL LENGTH SENSOR FOR APS (OPTION ONLY FOR THE LT/DLT VERSION) NOTE: To detect 11" x 15" size paper by APS in platen mode, an optional original length sensor is required. The sensor is available as a service part.
Page 77: Ads Sensor (Option)
CÓPIA NÃO CONTROLADA 2.8 ADS SENSOR (OPTION) Rev. 7/95 – A153, A155, and A156 copiers only – NOTE: For originals written on some types of red paper, dirty background may occur in ADS mode. For customers who mainly use such types of red paper originals, an optional ADS sensor which has a different sensitivity for red originals is available as a service part.
Page 78: Key Counter Holder (Option)
CÓPIA NÃO CONTROLADA Rev. 7/95 2.9 KEY COUNTER HOLDER (OPTION) CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the front right cover [A]. (See "Replacement and Adjustment - Outer Cover Removal".) 2. Remove the cap [B] with nippers. 3.
Page 79: Brand Decal Application Instructions (-10 And -22 Copiers Only)
CÓPIA NÃO CONTROLADA 2.10 BRAND DECAL APPLICATION INSTRUCTIONS (-10 AND -22 COPIERS ONLY) A153, A155, and A156 Copiers A157, A159, and A160 Copiers 1. Peel off the backing film [A]. 2. Attach the brand decal [B] to the indent in the front cover [C] as shown. A156/A160/A162 3-26 CÓPIA NÃO CONTROLADA...
Page 80: Service Tables
CÓPIA NÃO CONTROLADA SERVICE TABLES CÓPIA NÃO CONTROLADA...
Page 81 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 82: Service Remarks
CÓPIA NÃO CONTROLADA 1. SERVICE REMARKS 1.1 HANDLING THE DRUM The organic photoconductor (OPC) drum is comparatively more sensitive to light and ammonia gas than a selenium drum. 1. Never expose the drum to direct sunlight. 2. Never touch the drum surface with bare hands. When the drum surface is touched with fingers or becomes dirty, wipe it with a dry cloth or clean it with wet cotton.
Page 83: Drum Unit
CÓPIA NÃO CONTROLADA 1.2 DRUM UNIT 1. Make sure that the drum unit is set in position and the drum stay is secured with a screw when the main switch is turned on. If the drum unit is loose, poor contact of the drum connectors may cause electrical noise, resulting in unexpected malfunctions (RAM data may change in the worst case).
Page 84: Optics
CÓPIA NÃO CONTROLADA 1.4 OPTICS 1. When installing the exposure glass, make sure that the mark on the edge of the glass faces up. This makes sure that the correct side faces up; this side has a smoother surface and generates less static electricity. This is especially important when the ARDF is installed.
Page 85: Development Unit
CÓPIA NÃO CONTROLADA 1.6 DEVELOPMENT UNIT 1. Be careful not to nick or scratch the development roller sleeves. 2. Place the development unit on a sheet of paper after removing it from the copier. This prevents any small metal objects (staples, clips, E-rings, etc.) from being attracted to the development roller and getting inside the unit.
Page 86: Cleaning Section In The Drum Unit
CÓPIA NÃO CONTROLADA 1.8 CLEANING SECTION IN THE DRUM UNIT 1. When servicing the cleaning section, be careful not to damage the edge of the cleaning blade. 2. Apply setting powder to the surface of the drum when installing a new cleaning blade.
Page 87: Fusing Unit
CÓPIA NÃO CONTROLADA 6. Avoid storing paper in humid areas. At high temperature and high humidity, or at low temperature and low humidity, store paper in a plastic bag. This is especially important when a sorter stapler is installed. 7. Load the paper in the paper trays, LCT, and by-pass feed table the correct way up as indicated on the copy paper package.
Page 88: Service Program Mode
CÓPIA NÃO CONTROLADA 2. SERVICE PROGRAM MODE 2.1 SERVICE PROGRAM MODE OPERATION The service program (SP) mode is used to check electrical data, change modes, and adjust settings. 2.1.1 Service Program Mode Access Procedure How to enter the SP mode Press the following keys in sequence.
Page 89: Changing The Value Of An Sp Mode
CÓPIA NÃO CONTROLADA How to select the program number Program numbers are composed of two or three levels. –– –– 1st Level 2nd Level 3rd Level Program Number Program Number Program Number To input the required program number, select each program level in sequence.
Page 90: Memory Reset Procedures
CÓPIA NÃO CONTROLADA 2.2 MEMORY RESET PROCEDURES Before starting a memory reset procedure, be sure to remember the following: For SP3-123, SP7-804, SP7-808, SP7-810, and SP7-811, be sure to check again whether you really wish to use this SP mode before you press the key.
Page 91: Reset All Counters: Sp7-808
CÓPIA NÃO CONTROLADA 1. Enter the required SP mode. (Do not press after entering this SP mode until you are sure that you want to reset the counters.) NOTE: Before pressing the key, be sure to check again whether you have selected the correct SP mode number or not. 2.
Page 92: Drum Initialization: Sp3-123
CÓPIA NÃO CONTROLADA 2.2.3 Drum Initialization: SP3-123 CAUTION: If SP3-123 is performed, the V , and T/H correction levels and the drum rotation timer are reset. As a result, the old drum cannot be used any more. If the old drum is used after SP3-123 is performed, dirty background and/or toner scattering will appear on copies sooner or later because proper process control will not be applied to the drum.
Page 93: Reset All Memory (Sp5-801)
CÓPIA NÃO CONTROLADA 2.2.4 Reset All Memory (SP5-801) CAUTION: Reset All Memory mode (SP5-801) resets all the correction data for copy process control and all the software counters, and returns all modes and adjustments to the default settings. Normally, this SP mode should not be performed. This procedure is required only when replacing the RAM board or when the copier malfunctions due to a damaged RAM board.
Page 94 CÓPIA NÃO CONTROLADA 4. Refer to the "SP MODE FACTORY SETTING DATA" sheet located in the upper inner cover and enter the data that were stored in the following SP modes at the factory. • SP1-001: Registration Adjustment • SP2-001: Drum Charge Roller Voltage (for Copying) •...
Page 95: Service Program Mode Table
CÓPIA NÃO CONTROLADA 2.3 SERVICE PROGRAM MODE TABLE 1. A "†" after the mode name means that copies can be made while in this SP mode. 2. A "‡" after the default setting in the "Settings" column means that the actual factory setting for this is written on the data sheet in the front cover.
Page 96 CÓPIA NÃO CONTROLADA Rev. 6/16/95 Mode No. Function 2-201-xxx Development Bias Adjustments † 2-203 Development Bias Adjustment (for making V patterns) 2-206-xxx Development Bias Display † 2-207 Forced Toner Supply (shown as "Compulsory Toner Supply" on the display) 2-208-001 Toner Supply Mode Selection † 2-208-002 Toner Supply Ratio (TD Sensor Supply Mode) †...
Page 97 CÓPIA NÃO CONTROLADA Mode No. Function 4-201 Auto ADS Gain Adjustment 4-202 ADS Initial Gain Display † 4-203 ADS Actual Gain Display † 4-301 APS Sensor Function Check † 4-302 Optional APS Sensor (LT version only) † 4-303 APS A5/HLT Detection † 4-901 APS Size Priority (for F4 size) †...
Page 98 CÓPIA NÃO CONTROLADA Mode No. Function 5-802-xxx Free Run Mode 5-803 Input Check Mode † 5-804 Output Check Mode °5-810 SC Reset † 5-811 Used in Japan only. Do not change the factory setting. °5-812 Telephone Number Input † (A156 copier only) °5-816 Used in Japan only.
Page 99 CÓPIA NÃO CONTROLADA Mode No. Function °7-206 Stapler Counter † °7-301-xxx Total Copies by Magnification † °7-401 Total Service Call Counter † °7-402 SC Counter by 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.
Page 100: Sp Mode Table
CÓPIA NÃO CONTROLADA Rev. 7/95 2.3.2 SP Mode Table Mode No. Function Settings 1-001 Registration † Adjusts leading edge registration. 0 ~ 32 Default = 16 ‡ (0.5 mm per step [range: –8.0 mm to +8.0 mm]) 1-003-001 Paper Feed Adjusts the paper feed timing at 0 ~ 32 Timing †...
Page 101 CÓPIA NÃO CONTROLADA Mode No. Function Settings 1-105-002 Fusing Adjusts the temperature of the main and 0 ~ 5 Temperature secondary fusing lamps in energy saver (Type 1) Adjustment for mode. 0 ~ 4 Energy Saver (SP5-102 and SP5-305 are also related (Type 2) Mode †...
Page 102 CÓPIA NÃO CONTROLADA Mode No. Function Settings 2-001 Drum Charge Adjusts the voltage applied to the drum 0 - 32 Voltage charge roller during copying. Default: 16 Adjustment (for (0V) ‡ The adjustment factor set with this SP copying) † mode is added to the base voltage.
Page 103 CÓPIA NÃO CONTROLADA Mode No. Function Settings 2-206-001 Development Displays the development bias. Bias Display † SP2-206-001: Development bias used 2-206-002 for copying. SP2-206-002: Development bias used for making V sensor patterns. The first two digits are displayed in the reduce/enlarge indicator.
Page 104 CÓPIA NÃO CONTROLADA Mode No. Function Settings 2-214 TD Sensor Performs the TD sensor initial setting. 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, check SP2-220 to see if the sensor is working correctly.
Page 105 CÓPIA NÃO CONTROLADA Rev. 7/95 Mode No. Function Settings 2-802 Drum Charge Displays the drum charge roller Roller temperature [0 ~ 60°C]. Temperature † 2-812 Drum Reverse Adjusts the amount of the time for the 0 ~ 32 Rotation drum reverse rotation after each copy Default = 16 Adjustment †...
Page 106 CÓPIA NÃO CONTROLADA Mode No. Function Settings 3-112 Forced V After the "Start" key is pressed, forced Detection 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.
Page 107 CÓPIA NÃO CONTROLADA Rev. 7/95 Mode No. Function Settings °4-002 Exposure Lamp Displays the current exposure lamp 50.0 ~ 85.0 V Voltage Display voltage. † (0.5 V per step [Range: 50.0 V to 85.0 V]) For 115 V machines, the actual applied voltage = displayed value x 1.1412.
Page 108 CÓPIA NÃO CONTROLADA Mode No. Function Settings 4-102 Lens Error Adjusts the lens position to correct for 0 ~ 16 Correction † magnification in enlarge/reduce mode. Default: 8 (0%) ‡ (0.1% per step [Range: –0.8% to +0.8%]) 4-103 Focus Adjusts the 3rd mirror position to correct 0 ~ 150 Adjustment †...
Page 109 CÓPIA NÃO CONTROLADA Rev. 7/95 Mode No. Function Settings 4-901 APS Size Selects which copy paper size the 0: 8 " x 13" Priority (for F4 machine selects when the APS sensors 1: 8" x 13" " x 13"). " x 13" size) †...
Page 110 CÓPIA NÃO CONTROLADA Rev. 1/26/96 Mode No. Function Settings • °5-101 Auto Reset Inputs the auto reset time after the copier 0 ~ 999 Time Setting † enters standby, or disables auto reset. Default = 60 (1 second per step [Range: 1 ~ 999]) If "0"...
Page 111 CÓPIA NÃO CONTROLADA Rev. 1/26/96 Mode No. Function Settings • °5-110 Center Erase Adjusts the center erase margin width in A4 version Margin erase center mode. 8 ~ 25 Default = 20 Adjustment † LT version SP5-908 must be at 1 for this to have 0.32 ~ 1.00 any effect.
Page 112 CÓPIA NÃO CONTROLADA Rev. 7/95 Mode No. Function Settings • °5-404-001 User Code Resets the user code counters. Counter Clear † SP5-404-001: Resets the counter for the 5-404-002 user code that is now displayed in the reduce/enlarge indicator. SP5-404-002: Resets all the UC counters.
Page 113 CÓPIA NÃO CONTROLADA Rev. 7/95 Mode No. Function Settings 5-801 Memory All Resets all the correction data for process Clear † control and all software counters, and returns all modes and adjustments to the default settings. See Service Tables - section 2.2.4 for how to perform this SP mode.
Page 114 CÓPIA NÃO CONTROLADA Rev. 1/26/96 Mode No. Function Settings °5-905 APS A4/LT Specifies whether the machine selects 0: OFF Sideways LT sideways paper if the original is A4. 1: ON Priority † If "ON" is selected, LT sideways copy paper is selected automatically when the APS sensors detect an A4 sideways original.
Page 115 CÓPIA NÃO CONTROLADA Mode No. Function Settings • °6-002 ADF Free Size Specifies whether ADF free size setting 0: OFF Setting † is on or off. 1: ON Switch this on if the user makes copies of originals that contain paper of different sizes.
Page 116 CÓPIA NÃO CONTROLADA Mode No. Function Settings °6-101 Sorter Use this to specify which sorter is 0: No sorter Installation † installed. 1: A557 sorter 2: A556 sorter After setting this SP mode, the copier 3: Not used main switch must be turned off and on. 4: A568 sorter For the A554 and A555 sorter stapler, adapter only...
Page 117 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-002 Total Original Displays the total number of scanned Counter Display originals (DF + platen). † The first three digits are displayed in the reduce/enlarge indicator. Hold down the " " key to display the last three digits. •...
Page 118 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-204-001 Feed Unit Displays the total number of copies fed Counter † from each feed unit. 7-204-008 Without With SP Number Duplex Duplex SP7-204-001 1st tray — SP7-204-002 2nd tray 1st tray SP7-204-003 3rd tray 2nd tray SP7-204-004...
Page 119 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-501 Total Jam Displays the total number of copy jams Counter † plus original jams (max. 4 digits). (Copies + The first digit is displayed in the Originals) reduce/enlarge indicator. Hold down the "...
Page 120 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-801-001 Main ROM Displays the main ROM version. Version Display SP7-801-001: Copier main ROM version 7-801-004 † SP7-801-002: Paper tray unit main ROM version SP7-801-003: DF main ROM version SP7-801-004: Sorter stapler main ROM version The ROM version is displayed by a six- digit number.
Page 121 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-807-001 SC Counter Resets the total SC counter (SP7-401) Clear † and the individual counters for each type of Service Call (SP7-402). To reset the counters, press the key. °7-807-002 Copy Jam Resets the total copy jam counter Counter Reset (SP7-502) and the copy jam counters for †...
Page 122 CÓPIA NÃO CONTROLADA Mode No. Function Settings °7-810 Copy Counter Resets the following counters. • Clear Total Original Counter (SP7-002) • Total Copies by 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.
Page 123: Ut Mode And Sp Mode Cross Reference Table
CÓPIA NÃO CONTROLADA 2.4 UT MODE AND SP MODE CROSS REFERENCE TABLE UT Mode SP Mode Function 5-019 Paper Size Set 5-002 Feed Station Priority Selection 5-003 APS Priority Selection 6-010 Auto APS Select (DF) 5-103 Auto Tray Shift 5-013 Counter Up/Down Selection 5-017 Maximum Copy Quantity...
Page 124: Sp5-803 Sensor/Switch Input Check
CÓPIA NÃO CONTROLADA Rev. 7/95 2.5 SP5-803 SENSOR/SWITCH INPUT CHECK 1. Access SP5-803 (refer to section 2.1). 2. Select the required 3rd level program number using the keys. See the following page for a list of which 3rd level number to use for each component.
Page 125 CÓPIA NÃO CONTROLADA Rev. 7/95 3rd level Reading Sensor/Switch/Signal 2nd Tray Set Sensor Not set (Paper Tray Unit) 3rd Tray Paper End Sensor Paper detected Paper not detected (Paper Tray Unit) 3rd Tray Upper Limit Sensor Down (Paper Tray Unit) 3rd Tray Set Sensor Not set (Paper Tray Unit)
Page 126 CÓPIA NÃO CONTROLADA Rev. 7/95 3rd level Reading Sensor/Switch/Signal Sorter Stapler Set SW. Front Door Door Closed Door Open SW (A554) Door Safety SW (A554) Roller Drive Timing Sensor (A554)/Timing Sensor (A554) Duplex Entrance Sensor Duplex Turn Sensor Duplex Paper End Sensor Paper detected Paper not detected Upper Tray Switch...
Page 127: Sp5-804 Electrical Component Output Check
CÓPIA NÃO CONTROLADA Rev. 7/95 2.6 SP5-804 ELECTRICAL COMPONENT OUTPUT CHECK 1. Access SP5-804 (refer to section 2.1). 2. Select the required 3rd level program number using the keys. See below for a list of which 3rd level number to use for each component.
Page 128 CÓPIA NÃO CONTROLADA Rev. 7/95 3rd level No. Electrical Component Sorter stapler roller drive motor Sorter stapler turn gate SOL Sorter stapler bin lift motor Sorter stapler jogger motor Sorter stapler grip motor Sorter stapler motor Exhaust fan (Left) Exhaust fan (Right) 1 Optics cooling fan (1 or 2) Exposure lamp Quenching lamp, PTL...
Page 129: Sp5-019 Paper Size Setting
CÓPIA NÃO CONTROLADA Rev. 08/2001 2.7 SP5-019 PAPER SIZE SETTING 2.7.1 Paper Size Selection for the Paper Tray Unit, LCT, and By-pass Feed For the paper tray unit, LCT and by-pass feed, the paper size can be selected with SP5-019 using the following procedure. 1.
Page 130 CÓPIA NÃO CONTROLADA Rev. 8/2001 4. Select the required SP setting with the numeric keys in accordance with the following tables, then press the "Enter" key. NOTE: If you input the wrong SP setting by mistake, you can cancel it by pressing the "Clear/Stop"...
Page 131: Special Paper Size Selection For The 1St Tray
CÓPIA NÃO CONTROLADA Rev. 08/2001 2.7.2 Special Paper 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, A160, A161, A204, A208 and A212 copiers, or SP5-019-008 for A155, A159, A206 and A210 copiers.
Page 132: Practical Sp Mode Use Table
CÓPIA NÃO CONTROLADA 3. PRACTICAL SP MODE USE TABLE 3.1 REPLACEMENT AND CLEANING The following table shows the SP modes that must be done, and the order in which they must be done when the listed items are replaced or cleaned. (Priority Number) Replaced or Cleaned Item SP Mode...
Page 133: Data Display
CÓPIA NÃO CONTROLADA OTHER COPY IMAGE ADJUSTMENTS Mode No. Description Data SP2-101-001 Leading Edge Erase Margin 0-32 (0.5 mm/step) SP1-001 Registration 0-32 (0.5 mm/step) SP4-008 Vertical Magnification 0-32 (0.1%/step) SP4-101 Horizontal Magnification 0-32 (0.1%/step) SP4-103 Focus Adjustment 0-150 (0.05 mm/step) SP4-011 Lens Horizontal H.P.
Page 134: Test Points (Main Control Board)
CÓPIA NÃO CONTROLADA 4. TEST POINTS (MAIN CONTROL BOARD) Number Label Monitored Signal (RXB) (TXB) (TXA) (TXS) (RXS) (GND) Ground (+5 V) +5 V (TXL) (P-SENSOR) ID sensor output TP11 (TRANS-FB) Transfer current feed-back voltage TP12 (LAMP) Exposure lamp voltage feed-back voltage TP13 (T-SENSOR) Toner density sensor output...
Page 135: Preventive Maintenance Schedule
CÓPIA NÃO CONTROLADA Rev. 6/16/95 5. PREVENTIVE MAINTENANCE SCHEDULE 5.1 PM TABLE NOTE: The amounts mentioned as the PM interval indicate the number of copies. Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect A153/A155/A156 120K 240K 360K NOTE OPTICS Mirrors, Lens, Reflector Cotton pad with water, or...
Page 136 CÓPIA NÃO CONTROLADA A153/A155/A156 120K 240K 360K NOTE Separation Torque Limiter Clean with water. Replace (LCT, By-pass feed) these rollers as a set. Paper Feed Guide Plate Alcohol Relay rollers Alcohol or water Registration roller Alcohol or water Bottom Plate Pad (Paper Water tray, By-pass feed, LCT) CLEANING UNIT...
Page 137 CÓPIA NÃO CONTROLADA Rev. 6/16/95 A157/A159/A160 100K 200K 300K NOTE OPTICS Mirrors, Lens, Reflector Cotton pad with water, or blower brush Exposure Glass Alcohol or glass cleaner Exposure Lamp Replace if necessary Green Filter Dry cloth Scanner Guide Rails Dry cloth ADS, APS sensors Blower brush.
Page 138 CÓPIA NÃO CONTROLADA A157/A159/A160 100K 200K 300K NOTE CLEANING UNIT Drum Cleaning Blade Spread setting powder. See "Drum Cleaning Blade Replacement". Side Seal Replace if necessary Cleaning Entrance Seal Replace if necessary TRANSFER BELT UNIT Transfer Belt Spread setting powder. "See Transfer Belt Cleaning Blade Transfer Belt Cleaning Replacement"...
Page 139 CÓPIA NÃO CONTROLADA A157/A159/A160 100K 200K 300K NOTE SORTER ADAPTER (A568) Exit Drive Roller Alcohol or Water Upper Roller Alcohol or Water 120K 240K 360K NOTE PAPER TRAY UNIT (A549/A550) Pick-up, Feed, Separation Water, Replace these rollers Rollers as a set. Relay rollers Alcohol or water Bottom Plate Pad...
Page 140 CÓPIA NÃO CONTROLADA Note 1. Duplex 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. 4-59 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 141: Regular Pm Procedure
CÓPIA NÃO CONTROLADA Rev. 7/95 5.2 REGULAR PM PROCEDURE Every 120k (A153/A155/A156), or 100k (A157/A159/A160) Every 240k (A153/A155/A156), or 200k (A157/A159/A160) Make a copy of an OS-A3 test chart at 1. Make a Copy manual image density level 4. 1. Clean the mirrors, lens, and reflectors 2.
Page 142 CÓPIA NÃO CONTROLADA 1. Clean the inside of the cleaning unit and the seals. 4. Cleaning Unit (every 2. Replace the cleaning blade. 100 or 120 k) 1. Remove the old developer. 5. Development Unit (every 100 or 120 k) 2.
Page 143 CÓPIA NÃO CONTROLADA Rev. 7/95 1. Remove the transfer belt and clean the used toner tank with a blower brush or vacuum cleaner. 7. Transfer Belt Unit (every 100 or 120 k) 2. Clean the transfer belt. 3. Replace the transfer belt cleaning blade. Replace the transfer belt (every 200/240k).
Page 144 CÓPIA NÃO CONTROLADA 1. Clean the covers. 11. Exterior (every 100 or 120 k) Perform the following SP Modes in the following order. 12. Copy Process SP Mode Settings 1. SP2-214 TD Sensor Initial Setting 2. SP3-001 ID Sensor Initial Setting 3.
Page 145: Special Tools And Lubricants
CÓPIA NÃO CONTROLADA 6. SPECIAL TOOLS AND LUBRICANTS Part Number Description Q’ty A153 9001 Scanner Adjustment Tool 1 set A153 9004 WIPING CLOTH (Drum Charge Roller Cloth) 5420 9516 Test Chart - OS-A3 (10 pcs/set) 5420 9507 Digital Multimeter A008 9502 Silicone Grease - G40M 5442 9103 Launa Oil...
Page 146: Replacement And Adjustment
CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT CÓPIA NÃO CONTROLADA...
Page 147 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 148: Inner And Outer Covers
CÓPIA NÃO CONTROLADA 1. INNER AND OUTER COVERS 1.1 OUTER COVER REMOVAL 1.1.1 Front Cover 1. Open the front cover [A]. 2. Remove the front cover (2 pins). 1.1.2 Rear Cover 1. Loosen the 2 grounding screws for the upper holes. 2.
Page 149: Front Right Cover
CÓPIA NÃO CONTROLADA 1.1.4 Front Right Cover 1. Open the front cover and pull out the paper trays. 2. All models except A153/A157: Swing open the optional LCT unit [A]. 3. Remove the front right cover [B] (1 screw). 1.1.5 Rear Right Cover 1.
Page 150: Inner Cover Removal
CÓPIA NÃO CONTROLADA 1.2 INNER COVER REMOVAL 1.2.1 Upper Inner Cover 1. Open the front cover and slide out the toner bottle holder assembly [A] (1 screw and 1 knob screw). 2. Remove the upper inner cover [B] (2 screws). 1.2.2 Lower Right Inner Cover 1.
Page 151: Optics
CÓPIA NÃO CONTROLADA Rev.7/95 2. OPTICS 2.1 EXPOSURE GLASS REMOVAL 1. Remove the left scale [A] (2 shoulder screws). 2. Remove the 2 screws [B] securing the rear scale. 3. Grasp the front left corner of the exposure glass [C] and lift it up slightly. Then slide the exposure glass out from the rear scale.
Page 152 CÓPIA NÃO CONTROLADA Rev. 7/95 1. Turn off the main switch and unplug the machine. 2. Remove the exposure glass. (See Exposure Glass Removal.) 3. Move the scanner lamp to the fan duct in the rear frame (about 150 mm from the home position).
Page 153: Scanner Drive Belt Replacement
CÓPIA NÃO CONTROLADA 2.3 SCANNER DRIVE BELT REPLACEMENT 1. Remove the following parts: • • Platen cover [A] or DF Top cover [E] • • Left scale [B] (2 shoulder Rear scale [F] screws) • Rear cover [G] • Exposure glass [C] •...
Page 154 CÓPIA NÃO CONTROLADA 5. Remove the 1st scanner [A] from the scanner drive belt (1 screw). 6. Remove the 2nd scanner [B] from the scanner drive belt by loosening the 2 screws as shown. 7. Remove the left scale bracket [C] with the optics thermistor (2 screws and 1 connector).
Page 155 CÓPIA NÃO CONTROLADA 11. Remove the scanner motor belt [A] by removing the pulley [B] (1 Allen screw). 12. Remove both bearings [C] (1 E-ring each). 13. Remove the left cover and swing the main switch bracket [D] out of the way. 14.
Page 156: Scanner Positioning Adjustment
CÓPIA NÃO CONTROLADA 2.4 SCANNER POSITIONING ADJUSTMENT 1. Remove the following parts: • • Platen cover or DF Rear scale • • Left scale Rear cover • • Exposure glass Scanner HP. sensor • Top cover 2. Manually move the 1st scanner to about the center, and loosen the belt clamps of the 1st and 2nd scanner.
Page 157: 3Rd Scanner Motor Replacement
CÓPIA NÃO CONTROLADA 2.5 3RD SCANNER MOTOR REPLACEMENT 1. Remove the following parts: • • Platen cover or DF Lens cover • • Left scale Operation panel • • Exposure glass Left scale bracket • • Top cover Scanner HP. sensor bracket •...
Page 158: Lens Vertical Drive Motor Replacement
CÓPIA NÃO CONTROLADA 2.6 LENS VERTICAL DRIVE MOTOR REPLACEMENT [B] [C] 1. Perform steps 1 to 5 of the 3rd scanner motor replacement. 2. Remove the tension spring [A] and the lens drive wire [B]. 3. Remove the lens vertical drive motor bracket [C] (2 screws, 2 clamps, and 1 connector).
Page 159: Development And Toner Supply
CÓPIA NÃO CONTROLADA Rev. 7/95 3. DEVELOPMENT AND TONER SUPPLY 3.1 DEVELOPMENT UNIT REMOVAL 1. Turn off the main switch. 2. Open the front cover. 3. Remove the knob screw [A]. Swing out bottle holder [B] and pull down the lock lever [C]. Then slide out the bottle holder assembly [D] and swing out the bottle holder assembly.
Page 160: Developer Replacement
CÓPIA NÃO CONTROLADA 3.2 DEVELOPER REPLACEMENT 1. Take out the development unit and place it on a clean sheet. (See Development Unit Removal.) 2. Disconnect the connector [A] and separate the toner supply unit [B] from the development unit (2 screws). 3.
Page 161 CÓPIA NÃO CONTROLADA Rev. 7/95 4. Pour about half a pack of developer [E] into the development unit. Then rotate the two outer gears [F] and [G] as shown to distribute the developer evenly. Then pour in all the remaining developer and rotate the gears again. NOTE: Do not rotate the gears in the other direction, or developer will spill out.
Page 162: Toner Supply Motor Replacement
CÓPIA NÃO CONTROLADA 3.3 TONER SUPPLY MOTOR REPLACEMENT 1. Turn off the main switch and open the front cover. 2. Swing out the bottle holder and remove the toner bottle. 3. Remove the bottle holder from the copier (1 screw, 1 knob screw, and 1 connector).
Page 163: Around The Drum
CÓPIA NÃO CONTROLADA 4. AROUND THE DRUM 4.1 DRUM UNIT REMOVAL 1. Open the front cover and remove the development unit. (See Development Unit Removal.) 2. Turn the "A1" lever [A] counterclockwise to lower the transfer belt unit. 3. Remove the knob screw [B]. 4.
Page 164: Drum Replacement
CÓPIA NÃO CONTROLADA 4.2 DRUM REPLACEMENT 1. Pull out the drum unit from the copier. (See Drum Unit Removal.) 2. Remove the drum charge roller ass’y (see Drum Charge Roller Replacement). 3. Loosen the two screws [A] and remove the bearing holder [B]. 4.
Page 165 CÓPIA NÃO CONTROLADA 7. Insert a small screwdriver [A] under the cleaning blade release lever [B] to release the cleaning blade [C]. 8. Apply setting powder [D] to the surface of the drum, and rotate the drum with another screwdriver [E] until the area covered with setting powder has almost reached the cleaning blade.
Page 166: Pick-Off Pawl Replacement
CÓPIA NÃO CONTROLADA 4.3 PICK-OFF PAWL REPLACEMENT 1. Remove the drum unit. (See Drum Unit Removal.) 2. 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.
Page 167: Id Sensor Board Replacement
CÓPIA NÃO CONTROLADA 4.4 ID SENSOR BOARD REPLACEMENT 1. Remove the drum unit. (See Drum Unit Removal.) 2. Remove the ID sensor supporter [A] (one snap pawl). 3. Disconnect the connector [B]. 4. Pull the ID sensor board [C] sideways and remove the end [D] from the ID sensor board holder [E].
Page 168: Drum Cleaning Blade Replacement
CÓPIA NÃO CONTROLADA 4.5 DRUM CLEANING BLADE REPLACEMENT Good Good No good No good 1. Remove the drum unit. (See Drum Unit Removal.) 2. Remove the drum charge roller ass’y (see Drum Charge Roller Replacement). 3. Insert a small screwdriver [A] under the cleaning blade release lever [B] to release the cleaning blade holder [C].
Page 169 CÓPIA NÃO CONTROLADA 6. Apply setting powder [A] to the surface of the drum, and rotate the drum with another screwdriver [B] clockwise until the area covered with setting powder has almost reached the cleaning blade. 7. Remove the small screwdriver [C] so that the cleaning blade will press against the drum.
Page 170: Ptl Board Replacement
CÓPIA NÃO CONTROLADA 4.6 PTL BOARD REPLACEMENT 1. Remove the following parts: • Development unit • Drum unit • Main board 2. Lower the transfer belt unit and 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.
Page 171: Quenching Lamp Replacement
CÓPIA NÃO CONTROLADA 4.7 QUENCHING LAMP REPLACEMENT 1. Remove the following parts: • Development unit • Drum unit 2. Lower the transfer belt unit and place a sheet of paper [A] over the transfer belt. NOTE: This step prevents the quenching lamp from damaging the transfer belt if it falls.
Page 172: Erase Lamp Replacement
CÓPIA NÃO CONTROLADA 4.8 ERASE LAMP REPLACEMENT 1. Remove the following parts: • Development unit • Drum unit • Main board 2. Lower the transfer belt unit and 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.
Page 173: Drum Charge Roller Replacement
CÓPIA NÃO CONTROLADA 4.9 DRUM CHARGE ROLLER REPLACEMENT 1. Remove the following parts: • Development unit • Drum unit 2. Remove the drum charge roller ass’y [A] (2 screws, 1 connector). 3. Place the drum charge roller ass’y on a clean sheet of paper as shown. 4.
Page 174: Drum Charge Roller Terminal Replacement
CÓPIA NÃO CONTROLADA Rev. 6/16/95 4.10 DRUM CHARGE ROLLER TERMINAL REPLACEMENT 1. Remove the drum charge roller ass’y. 2. Place the drum charge roller ass’y [A] on a clean sheet of paper. 3. Remove the drum charge roller terminal [B] (1 screw). 4.
Page 175: Drum Charge Roller Cleaner Replacement
CÓPIA NÃO CONTROLADA 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]. A156/A160/A162 5-28 CÓPIA NÃO CONTROLADA...
Page 176 CÓPIA NÃO CONTROLADA 5. TRANSFER BELT UNIT 5.1 TRANSFER BELT UNIT REPLACEMENT – A153, A155, and A156 copiers – – A157, A159, and A160 copiers – A153, A155, and A156 copiers – – A157, A159, and A160 copiers 1. Remove the development unit, drum unit, and fusing unit 2.
Page 177 CÓPIA NÃO CONTROLADA 5.2 TRANSFER BELT REPLACEMENT 1. Remove the transfer belt unit. 2. While raising the knob [A], disconnect the connector [B]. NOTE: 1) Never touch the transfer belt. 2) Be careful not to bend the high voltage terminals [C]. 3.
Page 178 CÓPIA NÃO CONTROLADA 5.3 TRANSFER BELT CLEANING BLADE REPLACEMENT 1. Remove the transfer belt ass’y. (See "Transfer Belt Unit Removal".) 2. Remove the transfer belt cleaning blade [A] (three screws). 3. Install the new transfer belt cleaning blade. 4. Reinstall the transfer belt ass’y in the transfer belt unit. 5.
Page 179 CÓPIA NÃO CONTROLADA 5.4 DISPOSING OF COLLECTED TONER 1. Remove the transfer belt unit. (See "Transfer Belt Unit 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.
Page 180 CÓPIA NÃO CONTROLADA 6. PAPER FEED 6.1 BY-PASS PICK-UP, FEED, AND SEPARATION ROLLERS, AND TORQUE LIMITER REPLACEMENT 1. Remove the by-pass feed table [A] (1 clip, 1 connector). 2. Open the right door. 3. Remove the pick-up roller [B], feed roller [C], torque limiter [D], and the separation roller [E] (1 clip each).
Page 181 CÓPIA NÃO CONTROLADA 6.3 LOWER PAPER FEED UNIT REPLACEMENT (A153/A155/A156) 1. Remove the rear cover (see "Outer Cover Removal"). 2. Remove the right door [A] (2 connectors, 1 clip) or the LCT unit (see "LCT Unit Removal"). Steps 3 through 5 are required for machines with an LCT. 3.
Page 182 CÓPIA NÃO CONTROLADA 6.4 UPPER PAPER FEED UNIT REPLACEMENT (A153/A155/A156) 1. Remove the lower paper feed unit (see "Lower Paper Feed Unit Replacement"). 2. Remove the main control board unit [A] (4 screws, all connectors). 3. Remove the bracket [B] (2 screws). 4.
Page 183 CÓPIA NÃO CONTROLADA 6.5 PAPER FEED ROLLER REPLACEMENT (A157/A159/A160) 1. A157/A159 copiers only: Remove the front cover (see "Outer Cover Removal"). 2. Remove the paper feed tray [A] (2 screws). 3. Remove the stopper bracket [B] (1 screw). 4. Remove the feed roller assembly [C]. 5.
Page 184 CÓPIA NÃO CONTROLADA 6.6 REGISTRATION SENSOR REPLACEMENT 1. Remove the front cover (see "Outer 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.
Page 185 CÓPIA NÃO CONTROLADA 6.7 PAPER FEED CLUTCH REPLACEMENT (A157/A159/A160) 1. Remove the paper feed roller assembly (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.
Page 186 CÓPIA NÃO CONTROLADA 7. LCT 7.1 LCT UNIT REMOVAL 1. Remove the rear cover (see "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.
Page 187 CÓPIA NÃO CONTROLADA 7.2 LCT DRIVE BELT REPLACEMENT 1. Remove the LCT unit (see "LCT Unit Removal"). 2. Remove the upper belt cover [A] (4 screws). 3. Remove the lower belt cover [B] (1 screw). 4. Remove the front cover [C] (3 screws). 5.
Page 188 CÓPIA NÃO CONTROLADA 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). 5-41 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 189 CÓPIA NÃO CONTROLADA Rev. 7/95 8. FUSING 8.1 FUSING UNIT REMOVAL 1. Open the front cover. 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.
Page 190 CÓPIA NÃO CONTROLADA 8.2 FUSING LAMP REPLACEMENT 1. Remove the fusing unit (see "Fusing Unit Removal"). 2. Remove the fusing front cover [A] (1 screw). 3. Remove the pressure springs [B]. 4. Open the fusing exit cover [C] and remove the fusing upper unit [D] (4 screws).
Page 191 CÓPIA NÃO CONTROLADA Rev. 7/95 8.3 HOT ROLLER REPLACEMENT 1. Remove the fusing lamps (see "Fusing Lamp Replacement"). 2. Remove the hot roller stripper bracket [A] (2 screws). 3. Remove the hot roller assembly [B]. 4. Replace the hot roller [C] (2 C-rings, 1 gear, 2 bearings). NOTE: 1) Before installing the hot roller, peel off 3 cm (1 inch) from both ends of the protective sheet on the new one.
Page 192 CÓPIA NÃO CONTROLADA 8.4 PRESSURE ROLLER AND CLEANING ROLLER REPLACEMENT 1. Remove the fusing unit (see "Fusing Unit Removal"). 2. Remove the pressure springs and remove the lower fusing unit (4 screws). 3. Remove the lower fusing entrance guide [A] (2 screws). 4.
Page 193: Thermofuse Replacement
CÓPIA NÃO CONTROLADA 8.5 THERMISTOR REPLACEMENT 1. Remove the fusing unit (see "Fusing Unit Removal"). 2. Remove the hot roller assembly (see "Hot Roller Replacement"). 3. Remove the thermistor [A] (1 screw, 1 connector). NOTE: The standard pressure spring position is at the upper position. 8.6 THERMOFUSE REPLACEMENT 1.
Page 194: Duplex Unit
CÓPIA NÃO CONTROLADA 9. DUPLEX UNIT 9.1 FRICTION ROLLER REPLACEMENT 1. Remove the duplex unit (4 screws). 2. Remove the 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.
Page 195: Duplex Feed Roller Replacement
CÓPIA NÃO CONTROLADA 9.2 DUPLEX FEED ROLLER REPLACEMENT Feed Roller Stack Rolle See from the front side. 1. Pull out the duplex unit. 2. Remove the link bracket [A] (1 screw, 1 clip). 3. Remove the upper guide plate [B] and the lower guide plate [C] (1 clip). 4.
Page 196: Duplex Feed Motor Replacement
CÓPIA NÃO CONTROLADA 9.3 DUPLEX FEED MOTOR REPLACEMENT 1. Remove the duplex unit (4 screws). 2. Remove the link bracket [A] (1 screw, 1 clip). 3. Remove the upper guide plate [B] and the lower guide plate [C] (1 clip). 4.
Page 197 CÓPIA NÃO CONTROLADA 9. Disconnect the motor harness [A]. 10. Move the jogger fence inward and remove the paper feed assembly [B] (5 screws). 11. Remove the duplex feed motor assembly [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.
Page 198: Copy Quality Adjustment
CÓPIA NÃO CONTROLADA 10. COPY QUALITY ADJUSTMENT 10.1 LIGHT INTENSITY ADJUSTMENT (SP4-001) When: When replacing the drum - After performing SP3-123 (Drum initialization) and before exiting SP mode. Purpose: To maintain the correct light intensity. Adjustment standard: Level 2 of the gray scale on the OS-A3 test chart should be just visible on the copy when the 4th manual image density level is selected.
Page 199 CÓPIA NÃO CONTROLADA 6. If the image density is not correct, go through the following steps. 1) Enter SP4-001. 2) Change the exposure lamp voltage setting displayed in the reduce/enlarge indicator. Use the number keys and follow these rules: If image density is too dark, increase the setting If image density is too light, decrease the setting NOTE: The voltage can be set between 50 and 75 V in 0.5 V steps.
Page 200: Uneven Exposure Adjustment
CÓPIA NÃO CONTROLADA Rev. 7/95 10.2 UNEVEN EXPOSURE ADJUSTMENT When: If the exposure is uneven. Purpose: To maintain even exposure. Adjustment standard: The side-to-side variation of the gray scales on the test chart should be less than one level. How: Change the position of the exposure adjusting plates to make the light intensity from the exposure lamp even across its length.
Page 201: Image Area Bias Voltage Adjustment
CÓPIA NÃO CONTROLADA 10.3 IMAGE AREA BIAS VOLTAGE ADJUSTMENT 10.3.1 Development Bias Adjustment (SP2-201-001) When: If the image density at manual density level 4 cannot be adjusted to specification with the exposure lamp voltage (SP4-001) after performing SP3-123 (drum initialization) when the drum is replaced.
Page 202 CÓPIA NÃO CONTROLADA 10.3.2 Highest ID Level Bias (Manual ID Level 7) Adjustment (SP2-201-002) When: If a customer requests a lighter or darker copy image density at manual image density level 7. Purpose: To meet any customer’s requests about the image density at manual ID level 7.
Page 203: Toner Density Adjustment (Sp2-203)
CÓPIA NÃO CONTROLADA 10.4 TONER DENSITY ADJUSTMENT (SP2-203) When: If a customer wants to change the overall image density. Purpose: To change the proportion of toner by weight in the developer. How: SP2-203 changes the development bias used for making the V pattern.
Page 204: Detect/Fixed/Td Sensor Toner Supply
CÓPIA NÃO CONTROLADA 10.5 DETECT/FIXED/TD SENSOR TONER SUPPLY MODE SELECTION (SP2-208-001) When: If the ID sensor or the TD sensor is in an abnormal condition. Purpose: To leave the detect supply mode and to enter TD sensor supply mode or fixed supply mode. How: SP2-208-001 changes the toner supply mode.
Page 205: Toner Supply Ratio Selection
CÓPIA NÃO CONTROLADA 10.7 TONER SUPPLY RATIO SELECTION When: If the standard setting for the toner supply amount is not appropriate for the type of original in use. Purpose: To adjust the toner supply amount. The value of the toner supply ratio should match the proportion of black on typical originals used by the customer.
Page 206: Ads Sensor Automatic Adjustment (Sp4-201)
CÓPIA NÃO CONTROLADA 10.8 ADS SENSOR AUTOMATIC ADJUSTMENT (SP4-201) When: 1. If the ADS sensor output voltage is not within the adjustment standard after cleaning the optics. 2. After replacing the following parts: ADS board, Exposure lamp, RAM board on the main control board.
Page 207: Vertical Magnification Adjustment
CÓPIA NÃO CONTROLADA 10.10 VERTICAL MAGNIFICATION ADJUSTMENT (SP4-008) When: If vertical magnification is not within the adjustment standard. Purpose: To maintain proper vertical magnification. Less than ±1.0% difference between original Adjustment standard: and copy. How: SP4-008 changes the scanner speed compensation.
Page 208: Horizontal Magnification Adjustment (Sp4-101)
CÓPIA NÃO CONTROLADA 10.11 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP4-101) When: If horizontal magnification is not within the adjustment standard. Purpose: To maintain proper horizontal magnification. Less than ±0.5% difference in full size mode Adjustment standard: between original and copy. How: SP4-101 changes the lens home position. 1.
Page 209: Focus Adjustment In Full Size Mode (Sp4-103)
CÓPIA NÃO CONTROLADA 10.12 FOCUS ADJUSTMENT IN FULL SIZE MODE (SP4-103) When: If the copy in full size mode is out of focus. Purpose: To maintain correct focus in full size mode. How: SP4-103 changes the 3rd scanner home position. NOTE: Adjust the focus by checking the copies.
Page 210: Lead Edge Erase Margin Adjustment
CÓPIA NÃO CONTROLADA Rev. 7/95 10.15 LEAD EDGE ERASE MARGIN ADJUSTMENT (SP2-101-001) When: If the lead edge erase margin is not within the adjustment standard. Purpose: To maintain a proper lead edge erase margin. 2.5 ± 1.5 mm (0.1 ± 0.06") Adjustment Standard: How: SP2-101-001 changes the erase lamp off timing.
Page 211 CÓPIA NÃO CONTROLADA 3. If side-to side registration is not correct, go through the following steps: 1) Enter SP4-011. 2) Select the required 3rd level program number from the table below with the keys. 3rd Level Program Number Non-duplex Machines Duplex Machines –001 1st Tray...
Page 212: 4Th/5Th Mirror Height Adjustment
CÓPIA NÃO CONTROLADA Rev. 7/95 10.17 4TH/5TH MIRROR HEIGHT ADJUSTMENT When: If skewed images appear. Purpose: To maintain proper copy quality. How: Turn the 4th/5th mirror height adjustment screw. This changes the 4th/5th mirror height. CAUTION Never perform this adjustment unless you have positively verified that the source of the image skewing is optical and not in the paper path.
Page 213: Others
CÓPIA NÃO CONTROLADA 11. OTHERS 11.1 MAIN CONTROL BOARD REPLACEMENT NOTE: Never touch the surface of the RAM back up battery on the main board with a screwdriver or other metallic object. If the battery is short-circuited, RAM data will be destroyed in the worst case. 1.
Page 214: Ac Power Supply Board Replacement
CÓPIA NÃO CONTROLADA 11.2 AC POWER SUPPLY BOARD REPLACEMENT NOTE: 1. For 115V machines, check the fuse on the board before determining that 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.
Page 215: Dc Power Supply Board Replacement
CÓPIA NÃO CONTROLADA 11.3 DC POWER SUPPLY BOARD REPLACEMENT NOTE: Check the fuses (FU301, FU302, FU303, and 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.
Page 216: Cb High Voltage Supply Board Replacement
CÓPIA NÃO CONTROLADA 11.4 CB HIGH VOLTAGE SUPPLY 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).
Page 217: T High Voltage Supply Board Replacement
CÓPIA NÃO CONTROLADA 11.5 T HIGH VOLTAGE SUPPLY BOARD REPLACEMENT 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).
Page 218: Troubleshooting
CÓPIA NÃO CONTROLADA TROUBLESHOOTING CÓPIA NÃO CONTROLADA...
Page 219 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 220: Copy Quality
CÓPIA NÃO CONTROLADA 1. COPY QUALITY 1.1 INTRODUCTION This troubleshooting guide is compiled to help field engineers solve some of the more common field problems. However, it does not cover all the potential problems. We request your help in improving our troubleshooting documentation.
Page 221: Blank Copy (White Copy)
CÓPIA NÃO CONTROLADA 1.2 BLANK COPY (WHITE COPY) - Problem - White or almost white copy. - Possible Causes - 1. Charge is not applied. CB high voltage supply board failure • Poor high voltage terminal contact • • Broken drum charge roller Broken transfer belt contact clutch •...
Page 222 CÓPIA NÃO CONTROLADA - Action - Is the drum charge roller correctly installed? Install the drum charge roller correctly. Does the charge roller terminal properly contact the end of the drum charge roller? Replace the charge roller terminal. Is the drum charge roller broken? Replace the drum charge roller.
Page 223 CÓPIA NÃO CONTROLADA Does the drum rotate properly? Check drum drive mechanisms such as the drum drive belt and the drum pulleys. Check the following points: CN115-3 (Charge PWM) • (1) If the signal stays LOW after the Start key is pressed, replace the main control board.
Page 224: Dirty Background
CÓPIA NÃO CONTROLADA 1.3 DIRTY BACKGROUND - Problem - 1. Dirty background at image density level 4 (manual setting). 2. Copies made in ADS mode have a dirty background. - Possible Causes - 1. V correction failure • Very dirty optics (V correction cannot compensate) Deteriorated exposure lamp (maximum output cannot give sufficient •...
Page 225 CÓPIA NÃO CONTROLADA Rev. 7/95 - Action - Is the drum charge roller adjustment factor (SP2-001) at the correct value? Set SP2-001 to the factory set value. Adjust the exposure lamp voltage (SP4-001) Perform ADS initial setting (SP4-201) and forced V detection (SP3-105) Is the drum charge roller temperature is 0°C or 60°C Is the drum charge roller thermistor connector connected properly?
Page 226 CÓPIA NÃO CONTROLADA Is exposure lamp voltage (SP4-002) > Set exposure lamp voltage (SP4- 001) +10? Clean the optics and adjust the exposure lamp votage (SP4-001) Perform ADS initial setting (SP4-201) and forced V detection (SP3-105) Perform forced V detection Perform forced process control (SP3-902) until the target exposure lamp voltage (SP4-002) does not charge Is the background of the copy image still dirty?
Page 227 CÓPIA NÃO CONTROLADA Is the cleaning blade worn? Replace the cleaning blade. Are the erase lamp, quenching lamp and/or toner shield glass dirty? Clean the erase lamp, quenching lamp, and the toner shield glass, as required. If toner scattering occurs, see "1.13 Toner Scattering" later in this section. If dirty background occurs only in ADS mode, do the following: If the ADS voltage (SP4-202) is not within 2.7 ±...
Page 228: Uneven Image Density
CÓPIA NÃO CONTROLADA 1.4 UNEVEN IMAGE DENSITY - Problem - Uneven image density appears on copies. - Possible Cause - 1. Dirty optics 2.The exposure adjustment plates are out of positon 3. Dirty drum charge roller 4. Improper function of cross mixing in the development unit - Action - Does the uneven image area shift when a reduction copy is made? Is the optics section dirty?
Page 229: Vertical Black Bands
CÓPIA NÃO CONTROLADA 1.5 VERTICAL BLACK BANDS - Problem - Vertical black bands appear on the copy. - Possible Causes - 1. Dirty optics 2. Dust between the cleaning blade and the drum 3. The edge of the cleaning blade is deformed 4.
Page 230: Vertical Black Lines
CÓPIA NÃO CONTROLADA 1.6 VERTICAL BLACK LINES - Problem - Thin black lines appear on the copy. - Possible Causes - 1. Scratched cleaning blade 2. Dirty or scratched mirrors 3. Scratched or dirty drum 4. Scratched hot roller - Action - Do the black lines shift when a reduction copy is made? Clean or replace the exposure glass or mirrors.
Page 231: Vertical White Lines Or Bands-1
CÓPIA NÃO CONTROLADA 1.7 VERTICAL WHITE LINES OR BANDS—1 (DULL OR BLURRED) - Problem - Dull or blurred white lines appear on the copy. - Possible Causes - 1. Dirty or deteriorated drum charge roller 2. Damp or deformed inlet seal on the development unit - Action - Is the drum charge roller dirty? Clean the drum charge roller with a dry cloth.
Page 232: Vertical White Lines Or Bands-2 (Thin, Distinct)
CÓPIA NÃO CONTROLADA 1.8 VERTICAL WHITE LINES OR BANDS—2 (THIN, DISTINCT) - Problem - Vertical white lines appear on the copy. - Possible Causes - 1. Dirty or deteriorated drum charge roller 2. Paper dust on the edge of the cleaning blade 3.
Page 233: Horizontal Black/White Lines
CÓPIA NÃO CONTROLADA 1.9 HORIZONTAL BLACK/WHITE LINES - Problem - Black or white lines perpendicular to the paper feed direction appear on the copy image. - Possible Causes - 1. The drum is scratched. If black/white lines appear at 188.4 mm (7.42") intervals, the cause is a scratched drum or toner build-up.
Page 234: Skewed (Optical) Copy Image
CÓPIA NÃO CONTROLADA 1.10 SKEWED (OPTICAL) COPY IMAGE - Problem - The copy image is skewed (into a parallelogram shape). IMAGE The sides of the copy image are straight, but the leading and trailing edges are skewed. (This differs from skewing originating in the paper path.) - Possible Causes - 1.
Page 235: Toner Density Too High
CÓPIA NÃO CONTROLADA 1.11 TONER DENSITY TOO HIGH - Problem - 1. Dirty background appears on the copy. 2. The image density of black solid areas is too high. - Possible Causes - 1. The toner supply clutch keeps turning continuously. 2.
Page 236 CÓPIA NÃO CONTROLADA Make copies with a test chart and monitor the V value and the toner supply clutch function. Is the toner supply clutch controlled properly? (See the note at the bottom of the page.) Is the voltage at CN117-2 always 24V ? Replace the toner supply clutch.
Page 237: Toner Density Too Low
CÓPIA NÃO CONTROLADA 1.12 TONER DENSITY TOO LOW - Problem - 1. Light copies 2. Carrier on the copies. 3. Light spots appear in solid black areas. - Possible Causes - 1. The toner supply clutch does not rotate. 2. The copier entered fixed toner supply mode due to an abnormal sensor condition.
Page 238 CÓPIA NÃO CONTROLADA Does the toner supply clutch rotate? Is the voltage at CN117-2 always 24V ? Replace the toner supply clutch. Replace the main control board. Is the toner bottle nearly empty? Install a new toner bottle. Does the toner bottle drive motor rotate ? Is the voltage at CN121-2 always 24V ? Replace the toner bottle drive motor.
Page 239: Toner Scattering
CÓPIA NÃO CONTROLADA 1.13 TONER SCATTERING - Problem - Toner scatters from the development unit. - Possible Causes - 1. The toner density is too high. 2. The inlet seal on the development unit is out of position. 3. The developer has deteriorated. - Action - Is the toner density too high? See section 1.11 "Toner Density Too High".
Page 240: Unfused Copy
CÓPIA NÃO CONTROLADA 1.14 UNFUSED COPY - Problem - Solid black areas of the copy rub off easily. - Possible Causes - 1. The fusing pressure is too low. 2. The fusing temperature is too low. 3. The thermistor is malfunctioning. - Action - Adjust the position of the pressure springs to increase the fusing pressure.
Page 241: A Horizontal Thin Line Appearing Close To The Leading Edge
CÓPIA NÃO CONTROLADA 1.15 A HORIZONTAL THIN LINE APPEARING CLOSE TO THE LEADING EDGE - Problem - When an original has solid black areas at the trailing edge, toner transferred from the trailing edge onto the hot roller will appear on the next sheet of copy paper. - Action - Adjust SP2-101-002 (trailing edge erase margin) to leave a blank margin at the trailing edge of copies.
Page 242: Toner Supply Control
CÓPIA NÃO CONTROLADA 2. TONER SUPPLY CONTROL - Problem - The manual ID level or ADS indicator blinks. - Possible Causes - 1. Bad ID sensor board terminal contact 2. ID sensor adjustment error 3. Defective ID sensor 4. Dirty ID sensor 5.
Page 243 CÓPIA NÃO CONTROLADA Is V (SP3-103-001) between 0.01 and 2.5 V? Make 10 or more copies. Is V (SP3-103-001) between 0.01 and 2.5 V? Replace the ID sensor board. (SP3-103-002) within the 4.0 ± 0.2 V range? Also, is V ≈...
Page 244 CÓPIA NÃO CONTROLADA Is the TD sensor initial setting (SP2-220) within the 2.5 ± 0.1 V range? Replace the TD sensor. Is the TD sensor output (SP2-215-001) between 0.3 and 4.0 V? Replace the TD sensor. Set the toner supply mode to Detect Supply Mode. To do this, set SP2-208-001 to 3.
Page 245: Service Call Conditions
CÓPIA NÃO CONTROLADA 1. SERVICE CALL CONDITIONS 1.1 SUMMARY When a service call condition occurs, SC codes are displayed in the copy counter. The first three digits are displayed in the copy counter. Hold down the " " key to display the last two digits. •...
Page 246 CÓPIA NÃO CONTROLADA SC Code No. Description Classification E351 ID sensor adjustment error E352 TD sensor initial setting error E353 abnormal (over 2.5 V) E354 abnormal (under 2.5 V) E355 TD sensor upper limit detection abnormal E356 TD sensor lower limit detection abnormal E405 Transfer belt/drum charge roller position abnormal...
Page 247: Warning Sc Code Table
CÓPIA NÃO CONTROLADA 1.3 WARNING SC CODE TABLE SC code Description SC Timing Prohibited Function Note E501 Upper tray lift motor When the Paper feed from the error upper tray is upper tray selected E502 Lower tray lift motor When the lower Paper feed from the error tray is selected...
Page 248: C-Code Table
CÓPIA NÃO CONTROLADA (7) When an ADF is installed (8) When a sorter stapler is installed 1.4 C-CODE TABLE C-code Condition Message on LCD (A156 copier only) Front cover open Cover open Close the front cover Paper exit cover open —...
Page 249: Sc Code Descriptions
CÓPIA NÃO CONTROLADA 1.6 SC CODE DESCRIPTIONS E101: Exposure lamp error - Definition - [A] The exposure lamp stays on for longer than 10 seconds. The temperature around the optics reflector reaches 121°C. - Possible causes - • Exposure lamp open •...
Page 250 CÓPIA NÃO CONTROLADA E124: Scanner drive motor error - Definition - [B] During initialization and copying, the difference in the number of scanner drive motor steps between forward and reverse exceeds a certain number. - Possible causes - • Scanner movement too heavy •...
Page 251 CÓPIA NÃO CONTROLADA E143: Lens horizontal home position sensor error 2 - Definition - [B] The lens horizontal home position sensor remains actuated 2.0 seconds after the lens left the home position. - Possible Causes - • Lens horizontal home position sensor defective •...
Page 252 CÓPIA NÃO CONTROLADA E191: Auto ID sensor adjustment error (at the 1K copies process control) - Definition - [D] 1. ADS sensor output is lower than the 2.7 V target at the maximum gain for the sensor. 2. ADS sensor output is higher than the 2.7 V target at the minimum gain for the sensor.
Page 253 CÓPIA NÃO CONTROLADA E352: TD sensor initial setting error - Definition - [D] TD sensor output does not reach a value between 2.4 and 2.6 V when performing the developer initial setting procedure. - Possible Causes - • TD sensor defective •...
Page 254 CÓPIA NÃO CONTROLADA E356: TD sensor lower limit detection abnormal - Definition - [D] TD sensor output falls below than 0.3 volts during copy cycles. - Possible Causes - • TD sensor defective • Main control board defective • Toner supply system defective •...
Page 255 CÓPIA NÃO CONTROLADA E501: Main body upper tray lift motor abnormal (A153/A155 only) E502: Main body lower tray lift motor abnormal (A153/A155/A156 only) E503: Paper tray unit 1st tray lift motor abnormal (A549/A550 optional paper tray unit only) E504: Paper tray unit 2nd tray lift motor abnormal (A549/A550 optional paper tray unit only) E505: Paper tray unit 3rd tray lift motor abnormal (A549/A550 optional paper tray unit only)
Page 256 CÓPIA NÃO CONTROLADA E522: End fence jogger home position sensor error 1 (A156/A160 only) - Definition - [C] The end fence jogger home position sensor remains de-actuated for 8.0 seconds when the jogger home position initialization procedure is performed. - Possible Causes - •...
Page 257 CÓPIA NÃO CONTROLADA E525: Side fence jogger home position sensor error 2 (A156/A160 only) - Definition - [C] The side fence jogger home position sensor remains actuated for 1.0 second when the jogger home position initialization procedure is performed. - Possible Causes - •...
Page 258 CÓPIA NÃO CONTROLADA E544: Fusing overheat (back-up for E543) - Definition - [A] A fusing temperature of over 250 °C is detected 5 times by the main control board (this takes 5 seconds) - Possible Causes - • AC drive board defective (check the triac) •...
Page 259 CÓPIA NÃO CONTROLADA E621:Communication error between main control board and sorter - Definition - [B] The main CPU cannot start communication with the sorter properly. - Possible Causes - • Poor connection between the main control board and the sorter •...
Page 260 CÓPIA NÃO CONTROLADA E722 - Jogger Home Position Sensor Output Error (A554/A555) - Definition- [C] • When the jogger bar moves forward, the home position sensor takes over 100 ms to be deactivated. • When the jogger bar moves backward, the home position sensor takes over 800 ms to be activated.
Page 261 CÓPIA NÃO CONTROLADA E900: Total counter error 1 - Definition - [B] The total counter 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.
Page 262: Blown Fuse Conditions
CÓPIA NÃO CONTROLADA Rev. 7/95 2. BLOWN FUSE CONDITIONS Fuse Rating Working Symptom when turning on Voltage 115 V 220 ~ 240 V Main Switch DC Power Supply Board FU301 8 A/125 V 5 A/250 V 115 VAC No response FU302 6.3 A/125 V 6.3 A/250 V...
Page 263: Electrical Component Defects
CÓPIA NÃO CONTROLADA Rev. 7/95 3. ELECTRICAL COMPONENT DEFECTS 3.1 SENSORS Component Condition Symptom (Symbol) (When the main switch is turned on.) By-pass Feed 126-9~12 Open The copier does not turn on the bypass indicator. Paper Width (S1) Shorted The CPU cannot detect the proper paper size.
Page 264 CÓPIA NÃO CONTROLADA Rev. 7/95 Component Condition Symptom (Symbol) (When the main switch is turned on.) LCT Upper Limit 129-4 Open The bottom plate does not rise even if paper is placed in the LCT. [LCT machines only] (S11) Shorted The bottom plate rises and locks at the upper position.
Page 265 CÓPIA NÃO CONTROLADA Rev. 7/95 Component Condition Symptom (Symbol) (When the main switch is turned on.) Original Length-1 118-3 Open The CPU cannot detect the original size properly. APS and ARE do not function (S27) Shorted correctly. Duplex Paper End 486-5 Open "Copies Left In The Duplex Tray"...
Page 266: Switches
CÓPIA NÃO CONTROLADA 3.2 SWITCHES Component CN No. condition Symptom By-pass Feed 126-4 Open The copier does not turn on. Table (SW1) Shorted By-pass feed cannot be selected. Upper Tray 138-2 Open The copier does not turn on. [Non-duplex Shorted The user can select the tray even if it is machines only] not in place;...
Page 267 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 268: Appendix
CÓPIA NÃO CONTROLADA APPENDIX CÓPIA NÃO CONTROLADA...
Page 269 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 270 CÓPIA NÃO CONTROLADA APPENDIX PROCESS CONTROL TABLE FOR A153, A155, A156, A157, A159 AND A160 COPIERS Drum Charge Electrical Component Operation Panel TD Sensor ID sensor RAM Board Sensor Thermistor Manual ID Reproduction Original Drum Charge Drum Detected Item Toner Density V Pattern Pattern Pattern...
Page 271 CÓPIA NÃO CONTROLADA APPENDIX Table 5: EXPOSURE T/H Correction (V Pattern) for A153, A155, A156 copier Table 2: Table 1: Drum Charge Roller Drum Rotation Time (H) Correction Manual ID Correction 0 ≤ H < 40 40 ≤ H < 110 110 ≤...
Page 272: Tables & Sp Modes For Process Control
CÓPIA NÃO CONTROLADA APPENDIX TABLES & SP MODES FOR PROCESS CONTROL Table 9: Table 12: ID Correction Table 10: TSC: (Detect Supply Mode/TD Sensor Supply Mode) ID Correction (V Pattern) Step Development Bias Correction Voltage – V Supply Ratio TREF Initial 0.0196 Development Bias Correction...
Page 273: Auto Process Control Timing Chart
CÓPIA NÃO CONTROLADA APPENDIX AUTO PROCESS CONTROL TIMING CHART (Every time after 1000 copies) A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 274: Document Feeder A548
CÓPIA NÃO CONTROLADA AUTO REVERSE DOCUMENT FEEDER A548 CÓPIA NÃO CONTROLADA...
Page 275 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 276: Specifications
CÓPIA NÃO CONTROLADA Rev. 1/16/97 1. SPECIFICATIONS Original Size and Weight: Thick original mode (default mode) Use this setting for normal paper types Maximum A3, 11" x 17" Minimum B6 (sideways), 5 " x 8 " Weight 52 to 128 g/m Thin original mode Maximum A3, 11"...
Page 277: Component Layout
CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT MECHANICAL COMPONENTS 1. Original Stopper 7. Transport Belt 2. Press Lever 8. Pick-up Rollers 3. Original Table 9. Pull-out Roller 4. Exit Rollers 10. Feed Roller 5. Inverter Pawls 11. Friction Belt 6. Inverter Rollers A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 278: Electrical Components
CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENTS 1. Original Set Sensor 10 Feed-out Motor 2. Feed-in Cover Open Sensor 11. Feed-out Sensor 3. Stopper Solenoid 12. APS Start Sensor 4. Indicator Panel Lamps 13. DF Position Sensor 5. Feed-in Motor 14. Original Width Sensor - 1 6.
Page 279: Electrical Component Description
CÓPIA NÃO CONTROLADA 3. ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Motors Drives the feed-in system (pick-up, feed Feed-in and pull-out rollers, separation belt) Belt Drive Drives the transport belt Drives the feed-out and the inverter Feed-out system Sensors Detects whether originals have been Original Set placed on the original table...
Page 280: Installation
CÓPIA NÃO CONTROLADA 4. INSTALLATION ACCESSORY CHECK Check the 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.
Page 281: Installation Procedure
CÓPIA NÃO CONTROLADA Rev. 10\11\95 INSTALLATION PROCEDURE ⇒ Fiber Connector Plug [P] [E] [D] CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A]. 2. Attach the sponge retainer [B] to the top cover of the copier as shown. 3.
Page 282: Service Tables
CÓPIA NÃO CONTROLADA 5. SERVICE TABLES DIP SWITCHES DPS 101 Function Normal setting One-sided thin original mode free run with paper (35 cpm) One-sided thick original mode (normal mode) free run with paper (35 cpm) One-sided thick original mode (normal mode) fee run without paper (35 cpm) Two-sided mode free run with paper (35 cpm) Two-sided mode free run without paper (35 cpm)
Page 283: Variable Resistors
CÓPIA NÃO CONTROLADA VARIABLE RESISTORS VR No. Function Adjusts the registration in one-sided thin original mode. Adjusts the registration in two-sided original mode. LED No. Function Monitors the communication with the copier. FUSE FUSE No. Function Protects the 24 V line. A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 284 CÓPIA NÃO CONTROLADA 6. REPLACEMENT AND ADJUSTMENT TRANSPORT BELT REPLACEMENT 1. Turn off the main switch and lift up the DF. 2. Remove the grip [A] (3 screws). 3. Remove the 6 screws securing the transport belt assembly [B]. NOTE: Remove the two lower screws [C] first. 4.
Page 285 CÓPIA NÃO CONTROLADA FEED ROLLER REPLACEMENT 1. Turn off the main switch and 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.
Page 286 CÓPIA NÃO CONTROLADA FRICTION 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]. 7-11 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 287 CÓPIA NÃO CONTROLADA Rev. 11/96 ORIGINAL SET AND ORIGINAL WIDTH SENSOR REPLACEMENT 1. Turn off the main switch. 2. Remove the upper cover [A] (7 screws). 3. Remove the stopper solenoid spring [B]. 4. Remove the stopper/pressure lever shaft [C] (2 E-rings). 5.
Page 288 CÓPIA NÃO CONTROLADA VERTICAL REGISTRATION ADJUSTMENT 6.5.1 One Sided Thin Original Mode Note: • After replacing the DF main board, always do the Rough Adjustment using VR101 first. Then do the Fine Adjustment procedure. • At other times, just do the Fine Adjustment procedure. •...
Page 289 CÓPIA NÃO CONTROLADA Rev. 7/95 6.5.2 Two Sided Original Mode Note: • After replacing the DF main board, always do the Rough Adjustment using VR102 first. Then do the Fine Adjustment procedure. • At other times, just do the Fine Adjustment procedure. •...
Page 290 CÓPIA NÃO CONTROLADA SIDE-TO-SIDE REGISTRATION (DF POSITIONING) ADJUSTMENT Note: • First, adjust the DF side-to-side registration using the copier SP mode for this (see Replacement and Adjustment - Side-to-side Registration Adjusment in the copier manual). • Do the following adjustment only when the registration cannot be brought within the specification (0 ±...
Page 291 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 292 CÓPIA NÃO CONTROLADA PAPER TRAY UNIT A550/A549 CÓPIA NÃO CONTROLADA...
Page 293 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 294 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Configuration: Two-tray table or three-tray table Copy Paper Size: Maximum A3/11" X 17" Minimum B5/8 " X 11" Copy Paper Weight: 52 - 105 g/m , 14 - 28 lb Copy Paper Capacity: Approximately 500 sheets Paper Feed Speed: 20 ~ 40 copies/minute (A4 / 8 "X11"...
Page 295 CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT 1. Paper Tray 1 6. Lower Right Door 2. Pick-up Roller 7. Paper Lift Motors 3. Paper Feed Roller 8. Paper Tray 3 (A549 model only) 4. Relay Rollers 9. Paper Tray 2 5.
Page 296 CÓPIA NÃO CONTROLADA 2.2 DRIVE LAYOUT 1. Vertical Transport Roller Gears 6. Main Motor 2. Paper Feed Clutch 1 7. Relay Clutch 3. Paper Feed Clutch 2 8. Timing Pulley 4. Separation Roller Gears 5. Paper Feed Clutch 3 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 297 CÓPIA NÃO CONTROLADA 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on waterproof paper). Index Symbol Description Note Motors Main Drives all the components of the paper tray Tray lift 1 Raises the bottom plate in the paper tray Tray lift 2...
Page 298 CÓPIA NÃO CONTROLADA 3. INSTALLATION 3.1 ACCESSORY CHECK Check the quantity and 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.
Page 299 CÓPIA NÃO CONTROLADA Rev. 6/95 3.2 INSTALLATION PROCEDURE CAUTION Unplug the copier power cord before starting the following procedure. NOTE: Keep the shipping 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.
Page 300 CÓPIA NÃO CONTROLADA Rev. 10/11/95 ⇒ Fiber Connector Plug [P] For Copiers with an LCT: Do not lift the copier by holding the LCT unit. 3. Set the copier [B] on the paper tray unit [C]. Align the 2 pins [D] on the paper tray unit with the holes in the base plate of the copier.
Page 301 CÓPIA NÃO CONTROLADA 3.3 TRAY HEATER (OPTION) - Two-tray type - - Three-tray type - 1. Remove the rear cover [A]. 2. Two-tray type: Remove the second paper tray [B] (4 screws) and the lower front cover [C] (2 screws). Three-tray type: Remove the second and third paper feed trays [D] (4 screws each).
Page 302 CÓPIA NÃO CONTROLADA Rev. 7/95 4. SERVICE TABLES 4.1 DIP SWITCHES DIP SW 101 (Free Run Mode) Function Off On Off On Off Off Off Off Standard Factory Setting, PS280 Off On Off On On Off Off Off Standard Factory Setting, PS290 Speed in the free run mode: 200 mm/s Speed in the free run mode: 150 mm/s On Off...
Page 303 CÓPIA NÃO CONTROLADA 4.2 TEST POINTS NUMBER FUNCTION TP101 + 5V TP102 + 24V TP103 TP104 TXD (Transmit signal) TP105 RXD (Receive signal) TP106 A156/A160/A162 8-10 CÓPIA NÃO CONTROLADA...
Page 304 CÓPIA NÃO CONTROLADA 5. REPLACEMENT AND ADJUSTMENT 5.1 EXTERIOR COVER REMOVAL Rear Cover [A]: (2 screws) Front Lower Cover [B]: [Two-tray type only] 1. Slide out the cassettes. 2. Remove the front lower cover (2 screws). Right Front Cover [C]: 1.
Page 305 CÓPIA NÃO CONTROLADA 5.2 PAPER FEED CLUTCH REPLACEMENT 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the timing belt [A]. 3. Remove the drive unit [B] (2 screws, 2 connectors). 4. Remove the separation roller gear [C]. 5.
Page 306 CÓPIA NÃO CONTROLADA 5.3 PAPER FEED UNIT REPLACEMENT 1. Remove the paper feed clutch (see Paper Feed Clutch Replacement). 2. Remove the paper feed roller gear [A]. 3. Pull out all the trays. 4. Two-tray type only: Remove the front lower cover (see Exterior Cover Removal).
Page 307 CÓPIA NÃO CONTROLADA 5.4 FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER REPLACEMENT 1. Remove the paper 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).
Page 308 CÓPIA NÃO CONTROLADA 5.5 RELAY SENSOR REPLACEMENT 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the 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.
Page 309 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 310 CÓPIA NÃO CONTROLADA PAPER TRAY UNIT A553 CÓPIA NÃO CONTROLADA...
Page 311 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 312 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Configuration: Two-tray table Copy Paper Size: Maximum A3/11" x 17" Minimum B5/8 " x 11" Copy Paper Weight: 64 - 90 g/m , 17 - 24 lb Copy Paper Capacity: Approximately 250 sheets Paper Feed Speed: 20 ~ 35 copies/minute (A4 / 8 "X11"...
Page 313 CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT 1. Paper Tray 1 4. Lower Right Door 2. Paper Feed Rollers 5. Paper Tray 2 3. Relay Rollers 2.2 DRIVE LAYOUT 1. Vertical Transport Roller Gears 4. Main Motor 2.
Page 314 CÓPIA NÃO CONTROLADA 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on waterproof paper). Symbol Index No. Description Note Motors Main Drives all the paper tray components Circuit board Controls the paper feed tray unit in response PCB1 Interface board...
Page 315 CÓPIA NÃO CONTROLADA 3. INSTALLATION 3.1 ACCESSORY CHECK Check the quantity and 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.
Page 316 CÓPIA NÃO CONTROLADA Rev. 7/95 3.2 INSTALLATION PROCEDURE CAUTION Unplug the copier power cord before starting the following procedure. NOTE: Keep the shipping 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.
Page 317 CÓPIA NÃO CONTROLADA Rev.10/11/95 Fiber Connector Plug [P] For copiers with an LCT unit: Do not lift the copier by holding the LCT unit. 3. Set the copier [B] on the paper tray unit [C]. Align the 2 pins [D] on the paper tray unit with the holes in the base plate of the copier.
Page 318 CÓPIA NÃO CONTROLADA 3.3 TRAY HEATER (OPTION) 1. Remove the rear cover [A]. 2. Remove the second paper tray [B] (2 screws) and the lower front cover [C] (2 screws). 3. Install the tray heaters [D] (2 screws each). 4. Install the clamper [E] and clamp the heater harnesses. 5.
Page 319 CÓPIA NÃO CONTROLADA Rev. 7/95 4. SERVICE TABLES 4.1 DIP SWITCHES DIP SW 101 Function Off Off On On Off Off Off Off Standard Factory Setting Speed in the free run mode: 200 mm/s Speed in the free run mode: 150 mm/s On Off Bank type : 500 sheet type Off On...
Page 320 CÓPIA NÃO CONTROLADA 4.2 TEST POINTS NUMBER FUNCTION TP101 + 5V TP102 + 24V TP103 TP104 TXD (Transmit signal) TP105 RXD (Receive signal) TP106 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 321 CÓPIA NÃO CONTROLADA 5. REPLACEMENT AND ADJUSTMENT 5.1 EXTERIOR COVER REMOVAL Rear Cover [A]: (2 screws) Front Lower Cover [B]: 1. Slide out the cassettes. 2. Remove the front lower cover (2 screws). Right Front Cover [C]: 1. Remove the front lower cover [B]. 2.
Page 322 CÓPIA NÃO CONTROLADA 5.2 MAIN MOTOR REPLACEMENT 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the link bracket [A] (2 screws). 3. Remove the main motor bracket assembly [B] (2 screws, 2 connectors). 4. Remove the spring [C]. 5.
Page 323 CÓPIA NÃO CONTROLADA 5.3 CLUTCH REPLACEMENT First Paper Feed Clutch 1. Remove the rear cover (see Exterior Cover Removal). 2. Remove the bracket [A] (2 screws). 3. Remove the first paper feed clutch [B] (1 connector). Second Paper Feed Clutch 1.
Page 324 CÓPIA NÃO CONTROLADA 5.4 FEED ROLLER REPLACEMENT 1. Remove the paper feed tray [A] (2 screws). 2. Remove the stopper bracket [B] (1 screw). 3. Remove the feed roller assembly [C]. 4. Remove the feed roller [D]. • NOTE: When installing the feed roller assembly, the flat side of the roller should be facing down.
Page 325 CÓPIA NÃO CONTROLADA 5.5 RELAY SENSOR REPLACEMENT 1. Remove the rear cover (see 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.
Page 326 CÓPIA NÃO CONTROLADA SORTER STAPLER A554 CÓPIA NÃO CONTROLADA...
Page 327 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 328 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Paper Size for Bins: Sort or stack mode: Maximum: A3, 11" x 17" Minimum: A5, 5 " x 8 " lengthwise Staple mode: Maximum: A3, 11" x 17" Minimum: B5, 8 " x 11" Paper Weight for Bins: Sort mode: 52 - 93 g/m , 14 - 24 lb...
Page 329 CÓPIA NÃO CONTROLADA Staple Replenishment: Cartridge exchange (3,000 staples/cartridge) Power Source: DC 24V, 5V (form the copier) Power Consumption: 34 W Dimensions: 412 x 600 x 690 mm (W x D x H) (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) A156/A160/A162...
Page 330 CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT MECHANICAL COMPONENT LAYOUT 1. Proof Tray 9. Grip Assembly 2. Proof Tray Exit Rollers 10. Bin Support Block 3. Vertical Transport Rollers 11. Bins 4. Turn Gate 12. Support Bin 5. Bin Transport Belt 13.
Page 331 CÓPIA NÃO CONTROLADA DRIVE LAYOUT 4. Roller Drive Motor Pulley 11. Bin Lift Motor Pulley 8. Bin Lift Drive Belt 3. Rear Roller Drive Belt 7. Bin Lift Gears 2. Proof Tray Exit Roller Pulley (Rear) 6. Bin Lift Gear/Pulley 21.
Page 332 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point diagram (on waterproof paper). Index Symbol Name Function Motors Lifts and lowers the bins via a belt, gears, and Bin Lift wires.
Page 333 CÓPIA NÃO CONTROLADA Index Symbol Name Function Switches The bin lift motor stops when this switch detects Upper Lift Limit the upper limit position of the bins. The bin lift motor stops when this switch detects Wire Tension the lower limit position of the bins through the bin lift wire tension.
Page 334 CÓPIA NÃO CONTROLADA 3. ACCESSORY CHECK Check the quantity and condition of the accessories in the box as listed below: 1. Proof Tray ................1 2. Staple Cartridge ..............1 3. Staple Position Decal............1 4. Stepped Screw ..............1 5.
Page 335 CÓPIA NÃO CONTROLADA INSTALLATION PROCEDURE Make sure to follow the instructions below when unpacking and installing the sorter stapler. • Grasp the stay [A] when unpacking the sorter stapler. • Never hold the guide plate [B] when unpacking the sorter stapler.
Page 336 CÓPIA NÃO CONTROLADA NOTE: (1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to an another location in the future. (2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
Page 337 CÓPIA NÃO CONTROLADA 3. Remove the two plastic caps [A] from the copier 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.
Page 338 CÓPIA NÃO CONTROLADA 6. Remove the M4 x 8 round head screws from the left cover of the copier (A153/A155/A156 copiers: 2 screws [A], A157/A159/A160/A161/A162 copiers: 3 screws [A] and [B]). 7. Mount the sorter stapler mounting frame [C] on the copier as shown (4 –...
Page 339 CÓPIA NÃO CONTROLADA Rev. 10/11/95 Fiber Connector Plug [P] 12. Remove the Plug [P] from the rear 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.
Page 340 CÓPIA NÃO CONTROLADA 15. Open the front door of the sorter stapler and swing the staple unit [A] up. 16. Remove the green plastic clip [B] from the staple cartridge [C] and correct the position of the staple sheet [D] to make it flush with the other sheets in the cartridge.
Page 341 CÓPIA NÃO CONTROLADA Rev. 7/95 SERVICE TABLES (MAIN BOARD) DIP SWITCHES DIP SW 100 - Combinations other than those below are used only at the factory. Function Remarks Normal Machine Operation Sorter Free Run Stapler Free Run Sorter & Stapler Free Run Bin Sensor Adjustment (see section 6.6.2) To make a free run 1.
Page 342 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT STAPLER REMOVAL 1. Open the front door [A] of the sorter stapler and swing the staple unit [B] 2. Remove the staple unit cover [C] (1 screw). 3. Remove the stapler [D] (1 screw and 1 connector). 10-15 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 343 CÓPIA NÃO CONTROLADA GRIP ASSEMBLY REMOVAL 1. Remove the proof 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.
Page 344 CÓPIA NÃO CONTROLADA BIN REPLACEMENT 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). 10-17 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 345 CÓPIA NÃO CONTROLADA 5. Remove the support bin [A] and the bins [B] one by one. (1) Hold the bin [A or B] with both hands. (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.
Page 346 CÓPIA NÃO CONTROLADA 6. Install the support bin [A] and the bins [B] one by one. (1) Hold the bin top side up with both hands. (2) Tilt the bin so the left side is higher then the right side. (3) Pass the left wheel [C] through the slot [D].
Page 347 CÓPIA NÃO CONTROLADA BIN LIFT WIRE REPLACEMENT 6.4.1 Wire Removal 1. Remove the sorter stapler from the copier. 2. Remove the following parts: • Proof Tray [A] (1 screw). • Front Cover [B] (loosen 2 screws and remove 2 screws) •...
Page 348 CÓPIA NÃO CONTROLADA - Front side - 4. Remove the stapler unit [A] (3 screws and 1 connector [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.
Page 349 CÓPIA NÃO CONTROLADA - Rear side - 9. Remove the sorter power cord bracket (1 screw; see section 15.6.1). 10. Remove the main control board [A] (1 screw, 13 connectors, and 5 locking supports). 11. Remove the bin lift shaft cover [B] (2 screws). 12.
Page 350 CÓPIA NÃO CONTROLADA 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]. 10-23 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 351 CÓPIA NÃO CONTROLADA 6.4.2 Wire Installation [A] [E] Front Rear - Front - - Rear - 877.6 mm (34.55") 599mm (23.58") 1. Put the bead [A] at the end of the wire in the slot in the wire pulleys [B, 2.
Page 352 CÓPIA NÃO CONTROLADA VERTICAL TRANSPORT UNIT REMOVAL 1. Remove the sorter stapler from the copier. 2. Remove the proof tray, the front cover, the rear cover, and the upper cover. 3. Remove the upper hinge [A] (2 screws) and the sorter stapler set switch bracket [B] (1 screw).
Page 353 CÓPIA NÃO CONTROLADA MAIN CONTROL BOARD REPLACEMENT AND ADJUSTMENT 6.6.1 Main Control Board Replacement 1. Remove the proof 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.
Page 354 CÓPIA NÃO CONTROLADA 6.6.2 Bin Sensor 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. 10-27 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 355 CÓPIA NÃO CONTROLADA BELT TENSION ADJUSTMENT Bending = a 1. Remove the required covers for the following belt tension adjustments as listed below: Timing Belt [A] (Roller Drive Motor) ........Proof Tray Rear Cover Timing Belt [B] (Grip Motor) ..........Proof Tray Front Cover 2.
Page 356 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DEFECTS SENSORS Component Symptom Condition (Symbol) At main sw power-up Ready condition Bin Lift Open The Sorter Jam The Sorter Jam Timing -1 (stays indicator starts blinking. indicator starts blinking (S1) High) when copies are made ≥...
Page 357 CÓPIA NÃO CONTROLADA Component Symptom Condition (Symbol) At main sw power-up Ready condition Bin-LED Open The Sorter Jam indicator starts blinking when (S5) (stays sort/stack or staple mode is selected. Low) 140-4 Shorted (stays – – High) Bin-Photo. Open Stapling does not occur Tr (S6) (stays even though copying...
Page 358 CÓPIA NÃO CONTROLADA Component Symptom Condition (Symbol) At main sw power-up Ready condition Proof Tray Open The Sorter Jam Exit (S10) (stays – indicator starts blinking ≥ 4.0 V High) when copies are made in normal mode. 150-7 Shorted The Sorter Jam (stays indicator starts blinking.
Page 359 CÓPIA NÃO CONTROLADA SWITCHES Component Symptom CN No. Condition (Symbol) At main sw power-up Ready condition Open The Sorter Jam indicator The Sorter Jam indicator starts blinking. starts blinking when copies are made in sort/stack or staple Upper Limit 165-1 mode.
Page 360 CÓPIA NÃO CONTROLADA SORTER STAPLER A555 CÓPIA NÃO CONTROLADA...
Page 361 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 362 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Paper Size for Bins: Sort/Stack Modes: Maximum: A3, 11 x 17" Minimum: B5, 8 x 11" Paper Weight for Bins: Sorting: 52 ~ 157 g/m (14 ~ 42 lb) Stacking: 52 ~ 157 g/m (14 ~ 42 lb) Stapling: 52 ~ 80 g/m (14 ~ 21 lb)
Page 363 CÓPIA NÃO CONTROLADA Staple Replenishment: Cartridge exchange (2,000 staples/cartridge) 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"...
Page 364 CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT 1. Helical Wheels 5. Staple Unit 2. Jogger Plate 6. Bins 3. Grip Assembly 7. Proof Tray 4. Transport Rollers 11-3 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 365 CÓPIA NÃO CONTROLADA 2.2 DRIVE LAYOUT 1. Jogger Drive Belt 5. Jogger Motor 2. Transport Roller 6. Wheel Drive Belts 3. Helical Wheels 7. Bin Drive Motor 4. Transport Motor 8. Jogger Plate A156/A160/A162 11-4 CÓPIA NÃO CONTROLADA...
Page 366 CÓPIA NÃO CONTROLADA 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on waterproof paper). Symbol Index No. Description Note Motors Transport Drives the transport roller Jogger Drives the jogger plate to square the copies Bin Drive Drives the bins...
Page 367 CÓPIA NÃO CONTROLADA 3. INSTALLATION 3.1 ACCESSORY CHECK Check the quantity and condition of the accessories 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.
Page 368 CÓPIA NÃO CONTROLADA Rev. 7/95 3.2 INSTALLATION PROCEDURE – Incorrect Lifting Method – NOTE: When this unit is installed in the A157, A159, A160, A161, and A162 copiers, the sorter adapter (A568) should be installed before the sorter stapler. CAUTION Unplug the copier power cord before starting the following procedure.
Page 369 CÓPIA NÃO CONTROLADA – A153/A155/A156 copiers – – A157/A159/A160/A161/A162 copiers – 3. Remove the caps [A] with nippers. 4. For A153, A155, and A156 copiers: Fit the hooks [B] on the sorter stapler mounting frame [C] into the 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].
Page 370 CÓPIA NÃO CONTROLADA Rev. 10/11/95 – Incorrect Lifting Method – Fiber Connector Plug [P] 5. Install the sorter stapler [A] on the frame [1 M4 x 8 screw]. NOTE: Do not lift the sorter stapler by holding the entrance guide [B] when installing it.
Page 371 CÓPIA NÃO CONTROLADA 10. Open the front door [A] of the sorter stapler and swing the staple unit [B] 11. Remove the green plastic clip [C] from the staple cartridge and correct the position of the staple sheet [D] to make it flush with the other sheets in the cartridge.
Page 372 CÓPIA NÃO CONTROLADA Rev. 7/95 4. SERVICE TABLES 4.1 DIP SWITCHES DIP SW100 Switch No. Function Normal Setting Sorter Free Run Staple Free Run System Free Run Bin Jam Sensor Adjustment (see section 5.6) Using a Free Run Mode 1. Select the type of free run that you need using switches 2 and 3. 2.
Page 373 CÓPIA NÃO CONTROLADA 4.2 TEST POINTS Number Function TP100 +24 V TP101 +5 V TP102 4.3 LED Number Function LED100 Bin jam sensor status 4.4 VARIABLE RESISTOR Number Function Bin jam sensor (LED) adjustment VR100 (see Bin Jam Sensor Adjustment) A156/A160/A162 11-12 CÓPIA NÃO CONTROLADA...
Page 374 CÓPIA NÃO CONTROLADA 5. REPLACEMENT AND ADJUSTMENT 5.1 EXTERIOR COVER REMOVAL 1. Rear Cover [A] (2 screws) 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.
Page 375 CÓPIA NÃO CONTROLADA 5.3 GRIP ARM REPLACEMENT 1. Remove the front cover (see Exterior Cover Removal). 2. Remove the 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.
Page 376 CÓPIA NÃO CONTROLADA 5.4 BIN REPLACEMENT 1. Remove the front, rear, and top covers (see Exterior Cover Removal). 2. Remove the spring [A] and the grip cover [B] (2 screws). 3. Remove the upper stay bracket [C] (6 screws, 1 grounding wire, 1 connector).
Page 377 CÓPIA NÃO CONTROLADA 5.5 TRANSPORT MOTOR REPLACEMENT 1. Remove the sorter stapler [A] (1 screw, 1 chain). 2. Remove the lower plate [B] (3 screws). 3. Remove the entrance guide [C] (4 screws). 4. Remove the transport motor unit [D]. 5.
Page 378 CÓPIA NÃO CONTROLADA 5.6 BIN JAM SENSOR ADJUSTMENT After replacing the sorter 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.
Page 379 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 380 CÓPIA NÃO CONTROLADA SORTER A556 CÓPIA NÃO CONTROLADA...
Page 381 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 382 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Number of Bins: 20 bins + proof tray Paper Size for Bins: Sort/Stack Mode: Maximum - A3, 11" x 17" Minimum - A5, 5 " x 8 " Paper Weight: Sort/Stack Mode: 52 to 90 g/m (14 to 24 lb) Non-Sort/Stack Mode: 52 to 162 g/m (14 to 43 lb)
Page 383 CÓPIA NÃO CONTROLADA 2. 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 A156/A160/A162 12-2 CÓPIA NÃO CONTROLADA...
Page 384 CÓPIA NÃO CONTROLADA 3. ELECTRICAL COMPONENT 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) 12-3 A156/A160/A162 CÓPIA NÃO CONTROLADA...
Page 385 CÓPIA NÃO CONTROLADA 4. ELECTRICAL COMPONENT DESCRIPTIONS Index No. Name Function Symbol Motors Wheel Drive Motor Drives the wheel that changes the bin positions Roller Drive Motor Drives all rollers in the sorter paper path Sensors Paper Sensor Misfeed detection for the sorter Bin Home Position Detects when all bins are in the Sensor...
Page 386 CÓPIA NÃO CONTROLADA 5. INSTALLATION 5.1 ACCESSORY 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.
Page 387 CÓPIA NÃO CONTROLADA Rev. 7/95 5.2 INSTALLATION PROCEDURE NOTE: (1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to an another location in the future. (2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
Page 388 CÓPIA NÃO CONTROLADA Rev. 10/11/95 ⇒ Fiber Connector Plug [P] 3. Open the sorter top cover [A], and remove the front cover [B] (2 screws) and the rear cover [C] (4 screws). 4. Remove the two plastic caps [D] from the copier left cover with nippers. 5.
Page 389 CÓPIA NÃO CONTROLADA 9. Plug in the copier power cord and turn on the main switch. 10. Press the following sequence of keys to enter SP mode. → → → NOTE: (1) Hold the last key for more than 3 seconds. (2) Upon entering SP mode, "1"...
Page 390 CÓPIA NÃO CONTROLADA 6. REPLACEMENT AND ADJUSTMENT 6.1 EXIT ROLLER AND RUBBER BELT REPLACEMENT 1. Remove the sorter from 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.
Page 391 CÓPIA NÃO CONTROLADA Rev. 7/95 7. Remove the wheel sensor assembly [A] (1 screw). 8. Remove the sorter board (2 screws, 2 locking supports, and 3 connectors). 9. Remove the rear transfer wheel [B] (1 E-ring). NOTE: Be sure not to lose the pin [C] for the wheel. 10.
Page 392 CÓPIA NÃO CONTROLADA Rev. 7/95 6.2 PAPER SENSOR REPLACEMENT 1. Remove the sorter from the copier. 2. Remove the front cover (2 screws). 3. Remove the rear cover (4 screws). 4. Swing up the guide plate [A]. 5. Remove the inner cover [B] (4 screws). 6.
Page 393 CÓPIA NÃO CONTROLADA 6.3 TIMING BELT TENSION ADJUSTMENT 200 g (0.44 lb) −0 ADJUSTMENT STANDARD: 1 mm deflection under 200 g (0.44 lb) tension −0 1. Remove the front cover. 2. Loosen the two mounting screws [A] of the wheel drive motor [B]. 3.
Page 394 CÓPIA NÃO CONTROLADA SORTER A557 CÓPIA NÃO CONTROLADA...
Page 395 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 396 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS Number of Bins: 10 bins Paper Size for Bins: Sort/Stack Mode Maximum - A3, 11" x 17" Minimum - A5, 5 " x 8 " Paper Weight: Sort/Stack Mode: 64 to 90 g/m (17 to 24 lb) Non-Sort/Stack Mode: 52 to 162 g/m (14 to 43 Bin Capacity:...
Page 397 CÓPIA NÃO CONTROLADA 2. COMPONENT LAYOUT — Mechanical Components — 1. Bins 2. Transfer Wheel 3. Exit Roller 4. Upper Paper Guide 5. Lower Paper Guide 6. Bin Guide — Electrical Components — 1. Sorter Main Board 5. Bin Drive Motor 2.
Page 398 CÓPIA NÃO CONTROLADA 3. ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Motors Roller Drive Motor This dc motor drives the lower exit rollers. This reversible dc motor moves the bins up Bin Drive Motor or down. Switches Detects the rotation of the transfer wheel Wheel Switch and stops it in the correct position.
Page 399 CÓPIA NÃO CONTROLADA 4. INSTALLATION 4.1 ACCESSORY CHECK Check the quantity and condition 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.
Page 400 CÓPIA NÃO CONTROLADA 4.2 INSTALLATION PROCEDURE Rev. 7/95 NOTE: (1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to an another location in the future. (2) Proper installation of the shipping retainers is required in order to avoid any transport damage.
Page 401 CÓPIA NÃO CONTROLADA 3. Remove the cover plate [A] (2 screws). 4. Cut the links in the cover plate [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.
Page 402 CÓPIA NÃO CONTROLADA Rev. 10/11/95 Fiber Connector Plug [P] 8. Install the sorter [A] on the sorter holder bracket [B] (1 snap ring) as shown. 9. Remove the Plug [P] from the rear of the copier. 10. Connect the connector [C] to the socket [D] on the rear side of the copier. 11.
Page 403 CÓPIA NÃO CONTROLADA 5. PREPARATION FOR TRANSPORTATION CAUTION When removing and transporting the sorter, be careful not to carry it in a vertical position as the bins will become dislocated. CAUTION Refore moving the sorter, be sure to prepare it for transportation as follows.
Page 404 CÓPIA NÃO CONTROLADA 6. ROLLER DRIVE BELT REPLACEMENT 1. Remove the front cover [A] (1 screw). 2. Remove the rear cover [B] (1 screw) and the sorter hinge [C] (2 screws). 3. Remove the rear flat cover [D] (2 screws). 4.
Page 405 CÓPIA NÃO CONTROLADA 7. BIN GUIDE LUBRICATION Grease 501 rease 501 1. Remove the lower paper guide. (See Roller Drive Belt Replacement.) 2. Remove all bins [A] from 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).
Page 406 CÓPIA NÃO CONTROLADA APPENDIX CÓPIA NÃO CONTROLADA...
Page 407 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 408 CÓPIA NÃO CONTROLADA Rev. 4/98 A207 A208/A211 A212/A214 SERVICE MANUAL PN:RCFM5535 CÓPIA NÃO CONTROLADA...
Page 409 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 410 CÓPIA NÃO CONTROLADA Rev. 4/98 LEGEND PRODUCT CODE COMPANY GESTETNER RICOH SAVIN A156 2635TD FT5535 9035DL A153 2635 FT5035 9035 A160 2627TD FT4527 9027DL A157 2627 FT4027 9027 A162 2822TD FT4522 9220DL A161 2822 FT4022 9220 A207 2740TD FT5840 9400D...
Page 411 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 412 The Service Manual contains information r egarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program.
Page 413 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 414 CÓPIA NÃO CONTROLADA DIFFERENCES BETWEEN THE A204/A206/A207/A208/A210/A211 AND A153/A155/A156/A157/A159/A160 SERIES The models A204/A206/A207/A208/A210/A211 were based on the A153/A155/A156/A157/A159/A160. The following table lists the major differences between the 204/A206/A207/A208 /A210/A211 series and the A153/A155/A156/A157/A159/A160 series, and the pages to refer to in your service manual. Item (A204/A206/A207/ (A153/A155/A156/...
Page 415 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ the Service Manual) A208/A210/A211) A157/A159/A160) Temperature The elastic gum layer resistance Both the temperature and the Correction has been changed. Compared drum rotation time are monitored (formally known as the from the base copiers drum to apply corrections to the drum T/H correction)
Page 416 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160) the Service Manual) DRUM Drum Charge Roller The drum charge roller has been — modified to increase the chargeability especially at low temperatures. Also, the shape of the cleaner joint screw [A] has been changed as shown.
Page 417 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160) the Service Manual) OPTICS Toner Shield Glass The toner shield glass [A] is A toner shield glass and a green eliminated due to the change of filter is installed above the OPC shape of the green filter.
Page 418 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160) the Service Manual) PAPER FEED AND REGISTRATION Paper Feed System for All models use the FRR feed A153/A155/A156: the Paper Tray Feed system. FRR feed system Station Pg 1-32 A157/A159/A160: Corner separation system...
Page 419 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160 the Service Manual) Fusing Lamp The fusing lamp’s specifications are follows: , Pg 1-35, , Pg 2-109. Output Filament Operating Extension Temperature A204/A206/A207 Main 800 W 325 mm 185°C Secondary 350 W...
Page 420 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ the Service Manual) A208/A210/A211) A157/A159/A160 Cover Sheet The cover sheet function can be This function was only available performed by pressing a key on by accessing a UP mode. the operation panel.
Page 421 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 422 CÓPIA NÃO CONTROLADA Rev. 12/97 Table of Contents A204/A206/A207/A208/A210/A211 A212/A214 COPIER OVERALL MACHINE INFROMATION 1. SPECIFICATIONS ........1-1 2.
Page 423 CÓPIA NÃO CONTROLADA Rev. 12/97 8.3 ADS SAMPLING DURING COPYING ......1-31 9.
Page 424 CÓPIA NÃO CONTROLADA Rev. 04/2000 15.4 THERMISTOR AND THERMOFUSE REPLACEMENT ....1-105 15.5 FUSING LAMP REPLACEMENT ....... . 1-106 15.6 HOT ROLLER REPLACEMENT .
Page 425 CÓPIA NÃO CONTROLADA Rev. 12/97 11.2 STAPLER ........... 3-21 11.3 STAPLER UNIT PULL-OUT MECHANISM .
Page 426 CÓPIA NÃO CONTROLADA Rev. 12/97 3.3 BIN DRIVE MECHANISM ......... 4-8 3.4 BIN HOME POSITION .
Page 427 CÓPIA NÃO CONTROLADA Rev. 12/97 7.1.1 Toner Shield Glass ......... 5-18 7.2 SCANNER DRIVE .
Page 428 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 429 CÓPIA NÃO CONTROLADA Rev. 12/97 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3.
Page 430 CÓPIA NÃO CONTROLADA Rev. 12/97 SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1. Do not incinerate the toner bottle or the used toner. Toner dust may ignite suddenly when exposed to open flame. 2. Dispose of used toner, developer, and organic photoconductor according to local regulations.
Page 431 CÓPIA NÃO CONTROLADA A207/A208/A211 SERVICE MANUAL The A204 copier is based on the A153 copier. The A206 copier is based on the A155 copier. The A207 copier is based on the A156 copier. The A208 copier is based on the A157 copier. The A210 copier is based on the A159 copier.
Page 432 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 433: Specifications
CÓPIA NÃO CONTROLADA SPECIFICATIONS 1. SPECIFICATIONS NOTE: Only items marked with are different from A153, A155, A156, A157, A159, and A160 copiers. Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum: A3/11" x 17" Copy Paper Size: Maximum: A3/11"...
Page 434 CÓPIA NÃO CONTROLADA SPECIFICATIONS Power Source: 120 V/60 Hz: More than 12 A (for North America) 220 V ~ 240 V/50 Hz: More than 7 A (for Europe) 220 V/50 Hz: More than 7 A (for Asia) 110 V/60 Hz: More than 13 A (for Taiwan) 220 V/60 Hz: More than 7 A (for Saudi Arabia, Philippines)
Page 435 CÓPIA NÃO CONTROLADA SPECIFICATIONS Dimensions: Width Depth Height A204 copier 1,030 mm (40.6") 655 mm (25.8") 606 mm (23.9") A208 copier 900 mm (35.5") 655 mm (25.8") 606 mm (23.9") A206 and A207 copiers 1,258 mm (49.6") 655 mm (25.8") 606 mm (23.9") A210 and A211 copiers 1,128 mm (44.5")
Page 436 CÓPIA NÃO CONTROLADA SPECIFICATIONS Copy Number Input: Ten-key pad, 1 to 999 (count up or count down) Manual Image Density 7 steps Selection: Automatic Reset: 1 minute is the standard setting; it can be changed to a maximum of 999 seconds or no auto reset by SP mode.
Page 437 CÓPIA NÃO CONTROLADA SPECIFICATIONS • Optical anti-condensation heater • 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. A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 438: Machine Configuration
CÓPIA NÃO CONTROLADA MACHINE CONFIGURATION 2. MACHINE CONFIGURATION 2.1 COPIER A204V500.wmf A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 439: Optional Equipment
CÓPIA NÃO CONTROLADA MACHINE CONFIGURATION 2.2 OPTIONAL EQUIPMENT A204V501.wmf * 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 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 440 CÓPIA NÃO CONTROLADA MECHANICAL COMPONENT LAYOUT 3. MECHANICAL COMPONENT LAYOUT – A207 copier – 27 26 25 A204V502.wmf The fusing unit has been changed. (See Detailed Descriptions for more information.) NOTE: 1) The A204 copier is the same as the A207 copier except that the A204 does not have a duplex tray or an LCT.
Page 441: Mechanical Component Layout
CÓPIA NÃO CONTROLADA MECHANICAL COMPONENT LAYOUT – A211 copier – 28 27 26 25 A204V503.wmf The paper tray unit has been changed from the corner separation system to the FRR feed system. NOTE: 1) The A208 copier is the same as the A211 copier except that the A208 does not have a duplex tray or an LCT.
Page 442 CÓPIA NÃO CONTROLADA MECHANICAL COMPONENT LAYOUT 1. 3rd Mirror 20. Separation Roller 2. 2nd Mirror 21. Large Capacity Tray 3. 1st Mirror 22. Vertical Transport Rollers 4. Exposure Lamp 23. Paper Feed Roller 5. Lens 24. Friction Pad 6. Quenching Lamp 25.
Page 443: Electrical Component Descriptions
CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS 4. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout and the point to point diagram on the waterproof paper in the pocket for symbols and index numbers. : New or modified components Symbol Name Function Index No.
Page 444 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Exhaust Fan 2 Removes the heat from around the fusing (A204/A206/A207 unit. machines only) Scanner Drive Drives the 1st and 2nd scanners (dc stepper motor). 3rd Scanner Drive Drives the 3rd scanner (dc stepper motor). Lens Vertical Drive Shifts the lens vertical position.
Page 445 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. LCT Lower Limit Sends a signal to the CPU to stop lowering (LCT machines only) the LCT bottom plate. LCT Paper End Informs the CPU when the LCT runs out of (LCT machines only) paper.
Page 446 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Duplex Turn Detects the trailing edge of the copy paper (Duplex machines only) to determine the jogging timing, and detects misfeeds. Duplex Entrance Detects misfeeds. (Duplex machines only) Side Fence Jogger HP Detects the home position of the duplex (Duplex machines only) side fence jogger.
Page 447 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Transfer Belt Contact Controls the touch and release movement of both the transfer belt unit and the drum charge roller unit. Registration Drives the registration rollers. By-pass Feed Starts paper feed from the by-pass feed table or LCT.
Page 448 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Main Fusing Provides heat to the central area of the hot roller. Modified - see the "Fusing" section for details. Secondary Fusing Provides heat to both ends of the hot roller. Modified - see the "Fusing"...
Page 449 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Exposure Lamp Opens the exposure lamp circuit if the 1st scanner overheats. Counters Total Keeps track of the total number of copies made. Key (option) Used for control of authorized use. The copier will not operate until it is installed.
Page 450: Paper Feed Drive Layout
CÓPIA NÃO CONTROLADA PAPER FEED DRIVE LAYOUT 5. PAPER FEED DRIVE LAYOUT 5.1 A204/A206/A207/A208/A210/A211 A204V504.wmf Since A208, 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.
Page 451: Process Control
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6. PROCESS CONTROL 6.1 HALFTONE MODE This new mode is added to the A204/A206/A207/A208/A210/A211. If the user selects the halftone mode function on the operation panel, the machine changes the exposure lamp voltage, the development bias, and the drum charge voltage by the amounts shown below.
Page 452: Toner Supply Control During Copying
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.3 TONER SUPPLY CONTROL DURING COPYING The amount of toner supplied per unit of time (TS) has been changed from the base copier. Toner clutch on time is calculated by the following formula. S x AT x TSC ⁄ 100 Toner CL on time [ms] = (Formula 1) where: S...
Page 453: Toner Supply In Abnormal Sensor Conditions
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.4 TONER SUPPLY IN ABNORMAL SENSOR CONDITIONS If any sensor errors occur under detect supply mode, toner supply mode is changed automatically as shown below. Fallback Toner Display on Error Abnormal Condition Supply Mode Operation Panel ID Sensor When ID sensor output Fixed Supply Mode...
Page 454: Rpattern Correction
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.5 V PATTERN CORRECTION The values in the ID correction column of the table have been changed. correction ID Correction Drum Charge Roller Development Bias ±0 V Correction Voltage Correction Voltage –40 V –80 V ±0 V ±0 V 74 ~ 100...
Page 455: Temperature Correction
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.6 TEMPERATURE CORRECTION Temperature [°C] A204D506.wmf The temperature correction has changed as explained below. Also, the machine no longer does the drum rotation time correction. The temperature correction difference between the A204, A206, and A207 copiers and the A208, A210, and A211 copiers is a result of the difference in copy processing speed (240 mm/s for the A204, A206, and A207 copiers, compared with 200 mm/s for the A208, A210, and A211 copiers).
Page 456 CÓPIA NÃO CONTROLADA PROCESS CONTROL The temperature corrections are as shown below. • Temperature Correction (Copying) - Base drum charge voltage = –1,500 V • Temperature Correction (V Pattern) - Base drum charge = –1,370 V – A204, A206, and A207 – Drum Charge Roller Temperature Correction Temperature (°C)
Page 457: Toner End Recovery
CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.7 TONER END RECOVERY If the front cover safety switch or the main switch is turned off and on during a toner near-end/end condition, the machine will perform the toner end recovery procedure as shown on the flow chart on the next page. For the base copier, the toner end sensor checked for toner for a total of 10 seconds.
Page 458 CÓPIA NÃO CONTROLADA PROCESS CONTROL Toner End Condition Y e s Front Cover Switch or Main Switch Turned OFF/ O N ? Y e s Drum Drive, Development Clutch, Toner Supply Clutch, Toner Bottle Drive Motor Turn On. t = 0s. t ≥...
Page 459 CÓPIA NÃO CONTROLADA PROCESS CONTROL 6.8 SUMMARY NOTE: Only items marked with are different or revised from A153, A155, A156, A157, A159, and A160 copiers. A summary of process control and correction timing is shown below. Correction Timing Electrical Sensor Output Correction Corrected Value Automatic...
Page 460 CÓPIA NÃO CONTROLADA PROCESS CONTROL A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 461: Drum
CÓPIA NÃO CONTROLADA DRUM 7. DRUM 7.1 DRUM CHARGE ROLLER CLEANING The cleaning interval and the cleaning time have been changed. The drum charge roller cleaning routine is executed at the following intervals: 1) For 2 seconds at the end of every job For 5 seconds after the copy job interval set by SP2-901.
Page 462: Optics
CÓPIA NÃO CONTROLADA OPTICS 8. OPTICS 8.1 OVERVIEW 8.1.1 Halogen Lamp The specifications of the halogen lamp have been changed as follows. Note that the A204/A206/A207 models are faster, so they need more light during exposure. 115 V Machines 230 V Machines A204/A206/A207 97 V 310 W 85 V 310 W...
Page 463: Ads Sampling During Copying
CÓPIA NÃO CONTROLADA OPTICS 8.3 ADS SAMPLING DURING COPYING A204D511.wmf The position of the sampling area has been changed (in the base copier, it was 60 mm from the edge and 38 mm wide). 1-31 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 464: Paper Feed And Registration
CÓPIA NÃO CONTROLADA PAPER FEED AND REGISTRATION 9. PAPER FEED AND REGISTRATION 9.1 OVERVIEW - A204/206/207/208/210/211 - A204D512.wmf All of the above-mentioned models use the FRR system. This model has three paper feed stations: the large capacity tray feed station [A] (LCT machines only), the upper paper tray feed station (non-duplex machines only), and the lower paper tray feed station [B].
Page 465: Image Fusing (A204/A206/A207 Copiers)
CÓPIA NÃO CONTROLADA IMAGE FUSING (A204/A206/A207 COPIERS) 10. IMAGE FUSING (A204/A206/A207 COPIERS) 10.1 OVERVIEW A204D513.wmf 1. Thermofuse 7. Pressure Roller 2. Oil Supply Roller 8. Cleaning Roller 3. Oil Supply Roller Cleaning 9. Secondary Fusing Lamp Brush 10. Fusing Exit Rollers 4.
Page 466: Oil Supply Mechanism
CÓPIA NÃO CONTROLADA IMAGE FUSING (A204/A206/A207 COPIERS) 10.2 OIL SUPPLY MECHANISM [D] [A] A204D517.wmf The oil supply is necessary for a 40 cpm copier. An oil supply roller [A] is installed above the hot roller [B]. It is always in contact with the hot roller, and applies a light coat of silicone oil as the roller rotates.
Page 467: Fusing Lamp Control
CÓPIA NÃO CONTROLADA IMAGE FUSING (A204/A206/A207 COPIERS) 10.3 FUSING LAMP CONTROL A204D514.wmf There are two fusing lamps in the hot roller: the main fusing lamp (800 W) [A] and the secondary fusing lamp (350 W) [B]. The main fusing lamp has a much higher wattage that the one in the base copier, because it is the only lamp that is used during copying to control the operating temperature of the fusing unit (185°C).
Page 468 CÓPIA NÃO CONTROLADA IMAGE FUSING (A204/A206/A207 COPIERS) When the main switch turns on, the CPU checks the frequency of the power (AC) for 500 ms; this is done in case phase control mode is selected later. Then the CPU turns on the main fusing lamp. After 3 more seconds, the secondary fusing lamp is turned on.
Page 469: Installation
CÓPIA NÃO CONTROLADA INSTALLATION 11. INSTALLATION 11.1 COPIER ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Paper Size Decal.............. 1 2. Symbol Explanation Decal (except for the A207 copier) ..........1 3. Optional Zoom Function Decal ......... 1 4.
Page 470: Copier Installation Procedure
CÓPIA NÃO CONTROLADA INSTALLATION 11.2 COPIER INSTALLATION PROCEDURE CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets. A204I516.wmf A207/A208/A211 1-38 CÓPIA NÃO CONTROLADA...
Page 471 CÓPIA NÃO CONTROLADA INSTALLATION –A204/A206/A207 copiers– –A206/A207/A210/A211 copiers– A204I500.wmf –A208/A210/A211 copiers– A204I501.wmf A204I502.wmf CAUTION 1) Never lift the machine by holding the LCT, or the LCT will break. NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine is moved to another location in the future.
Page 472 CÓPIA NÃO CONTROLADA INSTALLATION –A207 copier– A204I503.wmf –A211 copier– A204I504.wmf 4. A207/A211 copiers only: 1) Pull out the duplex tray [A] and remove the strips of tape [B]. 2) Remove the guide roller stopper [C] and a sheet of paper [D]. 3) Open the upper duplex guide plate [E] and remove the strips of tape [F].
Page 473 CÓPIA NÃO CONTROLADA INSTALLATION –A204/A206/A207 copiers– A204I505.wmf –A208/A210/A211 copiers– A204I506.wmf A204I507.wmf 5. Open the front cover and swing out the toner bottle holder [A]. 6. Remove the strips of tape [B]. 7. Remove the switch actuator lock bracket [C] as shown. 8.
Page 474 CÓPIA NÃO CONTROLADA INSTALLATION A204I508.wmf A204I509.wmf 11. Remove the knob screw [A]. Swing out the bottle holder [B] and pull down the lock lever [C]. Then slide out the bottle holder assembly [D] and swing out the bottle holder assembly [D]. 13.
Page 475 CÓPIA NÃO CONTROLADA INSTALLATION A204I510.wmf A204I511.wmf 15. Disconnect the connector [A] and separate the toner supply unit [B] from the development unit (2 screws). 16. Pour about half a pack of developer [C] into the development unit. Then rotate the outer gear [D] as shown to distribute the developer evenly. Then pour in all the remaining developer and rotate the gear again.
Page 476 CÓPIA NÃO CONTROLADA INSTALLATION A204I512.wmf 19. Swing in the bottle holder assembly [A] so that the toner bottle holder [B] and the slide rail [C] are aligned straight. IMPORTANT: Do not swing the bottle holder fully into the machine before doing step 20.
Page 477 CÓPIA NÃO CONTROLADA INSTALLATION 24. Enter SP mode as follows: 1) Press the key. 2) Enter "107" using the numeric keys. A204I513.wmf 3) Hold down the key for more than 3 seconds. NOTE: 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.
Page 478 CÓPIA NÃO CONTROLADA INSTALLATION A204I518.img A204I514.wmf A204I517.wmf 28. Pull out the paper tray and load paper into it. (The paper size and direction for each tray should be as specified by the customer.) NOTE: The side and rear fences should be properly positioned. 29.
Page 479 CÓPIA NÃO CONTROLADA INSTALLATION A204I515.wmf 34. Install the optional platen cover [A] as follows if necessary: 1) Install 2 stud screws [B] on the top cover as shown. 2) Position the platen cover bracket [C] on the stud screws and slide it to the left.
Page 480: Auto Reverse Document Feeder (A663) Accessory Check
CÓPIA NÃO CONTROLADA INSTALLATION 11.3 AUTO REVERSE DOCUMENT FEEDER (A663) ACCESSORY CHECK Check 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.
Page 481: Auto Reverse Document Feeder (A663) Installation Procedure
CÓPIA NÃO CONTROLADA INSTALLATION 11.4 AUTO REVERSE DOCUMENT FEEDER (A663) INSTALLATION PROCEDURE A663I500.wmf [E] [D] A663I501.wmf A663I503.wmf A663I502.wmf CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [A]. 2. Attach the sponge retainer [B] to the top cover of the copier as shown. 3.
Page 482: 20-Bin Sorter Stapler (A664) Accessory Check
CÓPIA NÃO CONTROLADA INSTALLATION 11.5 20-BIN SORTER STAPLER (A664) ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Front Connection Bracket..........1 2. Rear Connecting Bracket ..........1 3. Cushion ................2 4. Entrance Guide Mylar for A204/A206/A207 copiers ..1 5.
Page 483: 20-Bin Sorter Stapler (A664) Installation Procedure
CÓPIA NÃO CONTROLADA INSTALLATION 11.6 20-BIN SORTER STAPLER (A664) INSTALLATION PROCEDURE A664I500.wmf A664I501.wmf A664I502.wmf CAUTION Unplug the copier power cord before starting the following procedure. NOTE: 1) Keep the shipping retainers after installing the machine. They will be reused if the machine will be transported to another location. 2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
Page 484 CÓPIA NÃO CONTROLADA INSTALLATION –A204/A206/A207 copiers– –A208/A210/A211 copiers– A664I503.wmf A664I504.wmf –A204/A206/A207 copiers– –A208/A210/A211 copiers– A664I505.wmf A664I506.wmf 4. Remove the two M4 x 8 round head screws [A] from the left cover of the copier. 5. Install the front connecting bracket [B] (2 screws M4 x 12) and the rear connecting bracket [C] (2 screws M4 x 12) on the copier.
Page 485 CÓPIA NÃO CONTROLADA INSTALLATION A664I507.wmf A664I508.wmf 7. Attach the two cushions [A] as shown. 8. Install the relay guide [B] (2 screws M4 x 6). 9. Open the front door of the sorter stapler and remove the screw [C] securing the locking lever [D], then lower the locking lever. 10.
Page 486 CÓPIA NÃO CONTROLADA INSTALLATION A664I509.wmf 14. If the gap between the top of the sorter stapler and the copier is too great, 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.
Page 487: 20-Bin Sorter Stapler (A658) Accessory Check
CÓPIA NÃO CONTROLADA INSTALLATION 11.7 20-BIN SORTER STAPLER (A658) ACCESSORY CHECK Check the accessories against the following 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.
Page 488: 20-Bin Sorter Stapler (A658) Installation Procedure
CÓPIA NÃO CONTROLADA INSTALLATION 11.8 20-BIN SORTER STAPLER (A658) INSTALLATION PROCEDURE A658I500.wmf A658I501.wmf A658I508.wmf CAUTION Unplug the copier power cord before starting the following procedure. When handling the sorter stapler, make sure to hold the parts shown [A]. Otherwise, the resulting damage may cause paper jams at the entrance.
Page 489 CÓPIA NÃO CONTROLADA INSTALLATION A658I502.wmf A658I503.wmf 3. Remove the two plastic caps [A] from 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. 1-57 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 490 CÓPIA NÃO CONTROLADA INSTALLATION A658I504.wmf A658I505.wmf A658I506.wmf 5. Remove the M4 x 8 round head screws (2 screws [A] for the A204/A206/A207 copiers, 3 screws [A] and [B] for A208/A210/A211 copiers) from the left cover of the copier. 6. Mount the sorter stapler mounting frame [C] on the copier as shown (4 screws M4 x 14 and 1 stepped screw [D]).
Page 491 CÓPIA NÃO CONTROLADA INSTALLATION A658I507.wmf 9. Connect the cable [A] and the optic cable [B]. 10. Install the chain [C] as shown. 11. Attach the staple position 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.
Page 492: Service Program Mode
CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12. SERVICE PROGRAM MODE 12.1 SERVICE PROGRAM MODE TABLE 1. Items written in bold italic letters are newly added service programs. 2. Items written in bold are modified service programs. 3. A "†" after the mode name means that copies can be made while in this SP mode.
Page 493 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Around the Drum 2-001 Drum Charge Voltage Adjustment (for copying) 2-002-xxx Drum Charge Voltage Display † 2-003 Drum Charge Voltage Adjustment (for making V patterns) 2-101-xxx Leading/Trailing Edge Erase Margin Adjustment † 2-201-xxx Development Bias Adjustments †...
Page 494 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function 4-013 Scanner Free Run 4-101 Horizontal Magnification Adjustment † 4-102 Lens Error Correction † 4-103 Focus Adjustment † 4-201 Auto ADS Gain Adjustment 4-202 ADS Initial Gain Display † 4-203 ADS Actual Gain Display † 4-301 APS Sensor Function Check †...
Page 495 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function °5-408 Number of Registered User Codes Display † • °5-410 User Code Reset Time Setting † °5-501-001 PM Interval Setting † °5-501-002 PM Interval Setting (PM Alarm Mode Setting) † 5-504 Used in Japan only.
Page 496 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Initial Copy Counter Setting for RDS/CSS Display † This is for use with features that are available only in Japan. °7-004 However, it does show the total number of copies that have been made.
Page 497 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12.1.2 SP Mode Table Mode No. Function Settings Registration † Adjusts leading edge registration. 0 ~ 32 1-001 Default = 16 ‡ (0.5 mm per step [Range: –8.0 mm to +8.0 mm]) Paper Feed Adjusts the paper feed timing at 0 ~ 32 Timing †...
Page 498 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Fusing Adjusts the temperature of the main 170 ~ 190 Temperature fusing lamp, which heats the central area Default = 185 Adjustment of the hot roller. (Type 1) 1-105-001 (Main Fusing The selected temperature is displayed in Default = 180 Lamp) †...
Page 499 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings CPM Down If this is set to 1 or 2, the machine drops 0: OFF 1: 160 °C Select † the cpm to the same as the Type 2 2: 170 °C (Type 1 only) model if it detects a temperature lower than the setting.
Page 500 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Leading/Trailing Adjusts the leading and trailing edge 0 - 32 Edge Erase erase margins. Default = 16 Margin SP2-101-001: Leading edge erase margin (SP 2-101-001) 2-101-001 Adjustment † SP2-101-002: Trailing edge erase margin Default = 18 (SP-101-002) (0.5 mm per step [Range: 0.0 mm to...
Page 501 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Toner Supply Selects the toner supply mode. 1: TD sensor Mode Selection In many cases, the machine will change supply mode † the toner supply mode automatically if 2: Fixed supply either the TD or ID sensor become mode unreliable.
Page 502 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Toner Supply Selects the toner supply ratio for detect 1: 7% Ratio supply mode. 2: 15% (Detect Supply For example, if the user normally makes 3: 30% 2-222 Mode) † copies of originals that are about 7% 4: 60% black, select the 7% setting for best...
Page 503 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings ID Sensor Displays the ID sensor outputs. Output Display † SP3-103-001: V 3-103-001 SP3-103-002: V 3-103-002 Normally, V = 0.01 ~ 2.50 V, V 4.0 ± 0.2 V (V ≈ 0.1) Forced V After the key is pressed, the initial...
Page 504 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Auto Process Selects whether auto process control 0: OFF Control Mode mode is off or performed at the interval 1: 1,000 copies Selection † shown. 2: 500 copies If the auto process control mode is 3: 200 copies switched off, V correction, V...
Page 505 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Lens Horizontal Adjusts the lens horizontal home position 0 ~ 32 HP Adjustment for each paper feed station. Default = 16 ‡ † (0.2 mm per step [Range: –3.2 mm to (only 4-011- +3.2 mm]) 008 is on the...
Page 506 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Auto ADS Gain Adjusts the ADS gain automatically to make the sensor output 2.7 ± 0.1 V. Adjustment Close the platen cover to prevent 4-201 external light from reaching the ADS sensor.
Page 507 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings APS 8 k/16 k Selects whether the machine can select 0: NO Detection † 8 k/16 k copy paper based on APS 1: YES (A4 versions sensor readings. only) If "YES" is selected, 8 k/16 k copy paper is selected under the following conditions: Size detected by Selected copy paper size...
Page 508 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Paper Size Set Sets the paper size for each paper tray For how to • °5-019-001 † and feed station. input the settings, see 5-019-008 section 2.7. Duplex Priority Specifies whether the copier defaults to 1: Duplex Selection duplex or single sided copies mode.
Page 509 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Image Shift This controls the left and right margin A4 version Margin width adjustment for both 1st and 2nd 0 ~ 15 Adjustment † side copies. Default = 5 SP5-107-001: Left Margin (1st side) LT version SP5-107-002: Right Margin (1st side) 0 ~ 0.60...
Page 510 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Auto Shut Off Selects the auto shut off time in NA version Time Setting † one-minute steps. 1 ~ 120 Default = 60 • The copier main switch is shut off °...
Page 511 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings User Code Deletes user code numbers. Number Clear † SP5-407-001: Deletes individual user code numbers. Enter the required user code at the • °5-407-001 numeric keys, then press key. (To see which 5-407-002 user codes are being used, use SP5-405.)
Page 512 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Free Run Mode Performs the free run SP5-802-001: Continuous free run SP5-802-002: One time free run 5-802-001 Before starting, close the platen or 5-802-002 ARDF. Press the key to start the free run.
Page 513 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Cover Mode Used to select whether to have front 1: Front/Back Selection † cover, front and back covers, or front 2: Front cover with image and back cover blank 3: Front with •...
Page 514 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings DF Free Run To start the DF free run, put some with Paper sheets of paper on the ARDF then press 6-009 key. Stop the free run by pressing key. This is a general free run controlled from the copier.
Page 515 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Staple Sheet Select whether there is a stapling limit for 0: OFF Limit † the sorter stapler. 1: ON OFF: Copies of up to 25 pages can be stapled for all paper sizes.
Page 516 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Initial Copy Counter Setting for RDS/CSS Display † 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. °7-004 The 4th ~ 6th digits are displayed in the reduce/enlarge indicator.
Page 517 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Stapler Counter Displays the total number of stapling † runs. °7-206 The first three digits are displayed in the reduce/enlarge indicator. Hold down the " " key to display the last three digits. •...
Page 518 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Total Jams by Displays the total copy paper jam counts Location † by location (max. 4 digits). SP Number Paper Jam Location Symbol SP7-504-001 SP7-504-002 °7-504-001 SP7-504-003 SP7-504-004 7-504-006 SP7-504-005 SP7-504-006 The first one digit is displayed in the reduce/enlarge indicator.
Page 519 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Main ROM Displays the main ROM version. Version Display SP7-801-001: Copier main ROM version † SP7-801-002: Paper tray unit main ROM version SP7-801-003: DF main ROM version SP7-801-004: Sorter stapler main ROM version The ROM version is displayed by a six- digit number.
Page 520 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Copy Jam Resets the total copy jam counter Counter Reset (SP7-502) and the copy jam counters for † individual locations (SP7-504). °7-807-002 (displayed as To reset the counters, press the key.
Page 521 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Feed Unit Reset one of the following counters by Counter Clear † pressing the key. SP Number Without Duplex With Duplex SP7-816-001 1st tray — SP7-816-002 2nd tray 1st tray °7-816-001 SP7-816-003 3rd tray...
Page 522 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12.2 UP MODE AND SP MODE CROSS REFERENCE TABLE UP Mode SP Mode Function 5-019 Paper Size Set 5-002 Feed Station Priority Selection 5-003 APS Priority Selection 6-010 Auto APS Select (DF) 5-103 Auto Tray Shift 5-013 Counter Up/Down Selection 5-017...
Page 523 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 13. PREVENTIVE MAINTENANCE SCHEDULE 13.1 PM TABLE NOTE: The amounts mentioned as the PM interval indicate the number of copies. Symbol key: C: Clean R: Replace L: Lubricate I: Inspect A204/A206/A207 120 k 240 k 360 k NOTE OPTICS Mirrors, Lens, Reflector...
Page 524 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE A204/A206/A207 120 k 240 k 360 k NOTE PAPER FEED (for each paper feed station) Pick-up, Feed, Clean with water. Replace these Separation Rollers rollers as a set. (Paper tray) Pick-up, Feed, Clean with water. Replace these Separation Rollers rollers as a set.
Page 525 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE A204/A206/A207 120 k 240 k 360 k NOTE Oil Supply Roller Cleaning Brush Fusing Exit Rollers Turn Guide Transport Rollers Hot Roller Strippers Oil Supply Roller Replace if necessary Bushing (One-way) DUPLEX TRAY Clutch Spring Mobil Temp 78.
Page 526 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE A208/A210/A211 120 k 240 k 360 k NOTE Erase Lamp Dry cloth Quenching Lamp Dry cloth Pick-off Pawls Dry cloth Pre-Transfer Lamp Dry cloth and blower brush DEVELOPMENT UNIT Developer Do SP2-214 after replacement. Side Seal Development Filter Entrance Seal...
Page 527 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE A208/A210/A211 120 k 240 k 360 k NOTE Fusing Lamps Replace if necessary Hot Roller Pressure Roller Suitable solvent Fusing Thermistors Suitable solvent Hot and Pressure Replace if necessary Roller Bearings Fusing Antistatic Brush Replace if necessary Cleaning Roller Suitable solvent...
Page 528 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 80 k 160 k 240 k NOTE AUTO DOCUMENT FEEDER (A663) (for originals) DF64 Transport Belt Belt cleaner Friction Belt Water Separation Roller Water NOTE 20-BIN SORTER STAPLER (A664) ST30 Transport and Exit Rollers Alcohol or water Bins Alcohol or water...
Page 529 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 13.2 REGULAR PM PROCEDURE Every 120 k (A204/A206/A207), or 100 k (A208/A210/A211) Every 240 k (A204/A206/A207), or 200 k (A208/A210/A211) 1. Make a Copy Make a copy of an OS-A3 test chart at manual image density level 4.
Page 530 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Clean the inside of the cleaning unit and the 4. Cleaning Unit seals. (every 120 k) 2. Replace the cleaning blade. 1. Remove the old developer. 5. Development Unit (every 120 k) 2. Clean the development unit and seals. 3.
Page 531 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Remove the transfer belt and clean the used 7. Transfer Belt Unit toner tank with a blower brush or vacuum (every 120 k) cleaner. 2. Clean the transfer belt. Replace the transfer 3. Replace the transfer belt cleaning blade. belt (every 240 k).
Page 532 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Clean the covers. 11. Exterior (every 120 k) 12. Development Unit Perform the following SP Modes in the following (every 120 k) order. 1. SP2-214 TD Sensor Initial Setting 2. SP3-001 ID Sensor Initial Setting 3.
Page 533 CÓPIA NÃO CONTROLADA SPECIAL TOOLS AND LUBRICANTS 14. SPECIAL TOOLS AND LUBRICANTS : New or modified items Part Number Description Q’ty A153 9001 Scanner Adjustment Tool A153 9004 WIPING CLOTH (Drum Charge Roller Cloth) 5420 9516 Test Chart - OS-A3 (10 pcs/set) 5420 9507 Digital Multimeter A008 9502...
Page 534 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15. REPLACEMENT AND ADJUSTMENT 15.1 FUSING (A204/A206/A207) NOTE: For the A208/A210/A211, use the parts and procedures for the A153/A155/A156 in the base copier manual. 15.1.1 FUSING UNIT REMOVAL A204R500.wmf CAUTION Before completely removing the fusing unit, support the bottom of the fusing unit.
Page 535 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.2 HOT ROLLER STRIPPER REPLACEMENT A204R501.wmf 1. Remove the fusing 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). 1-103 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 536 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.3 CLEANING ROLLER REPLACEMENT A204R502.wmf 1. Remove 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). A207/A208/A211 1-104 CÓPIA NÃO CONTROLADA...
Page 537 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.4 THERMISTOR AND THERMOFUSE REPLACEMENT A204R503.wmf A204R508.wmf 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the fusing front cover [A] (1 screw). 3. Disconnect the 4 connectors [B]. 4. Remove the fusing upper unit [C] (4 screws). 5.
Page 538 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.5 FUSING LAMP REPLACEMENT A204R504.wmf 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the fusing front cover and the fusing upper unit. (See Thermistor and Thermofuse Replacement.) 3. Remove the lamp holders [A] (1 screw each). 4.
Page 539 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.6 HOT ROLLER REPLACEMENT A204R505.wmf CAUTION The fusing unit may be hot. 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the fusing lamps. (See Fusing Lamp Replacement.) 3. Turn down the release pressure lever [A], as shown (1 screw at each end).
Page 540 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.7 PRESSURE ROLLER REPLACEMENT A204R506.wmf CAUTION The fusing unit may be hot. 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the hot roller. (See Hot Roller Replacement.) 3. Remove the lower fusing entrance guide [A] (2 screws). 4.
Page 541 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.8 OIL SUPPLY ROLLER AND OIL SUPPLY ROLLER CLEANING BRUSH REPLACEMENT A204R507.wmf 1. Remove the fusing unit. (See Fusing Unit Removal.) 2. Remove the fusing front cover and the fusing upper unit. (See Thermistor And Thermofuse Replacement.) 3.
Page 542 CÓPIA NÃO CONTROLADA SC CODE DESCRIPTIONS 16. SC CODE DESCRIPTIONS Only the following SC codes have been changed or added from the base copier. E720 - Timing Sensor (Roller Drive) Output Error (A555/A658/A664) - Definition - [B] When the roller drive/transport motor is turning, the timing sensor takes over 500 ms to change.
Page 543 CÓPIA NÃO CONTROLADA SC CODE DESCRIPTIONS E723 - Grip Home Position Sensor Output Error (A555/A658/A664) - Definition- [C] • When the grip motor rotates forwards, 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.
Page 544 CÓPIA NÃO CONTROLADA ROM HISTORY Rev. 04/2000 17. MAIN PCB ROM HISTORY A207/A208/A211 Firmware Modification History (Main PCB Copier) Description of Modification Part Number Serial Number Initial Production A2045107C From initial production. The Main PCB ROM has been upgraded to meet A2045120 July 1997 production.
Page 545 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 546 CÓPIA NÃO CONTROLADA AUTO REVERSE DOCUMENT FEEDER A663 The A663 ARDF is based on the 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 547 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 548 CÓPIA NÃO CONTROLADA SPECIFICATIONS 1. SPECIFICATIONS The specifications are the same as for the A548 ARDF. Original Size and Weight: Thick original mode (default mode) Use this setting for normal paper types Maximum A3, 11" x 17" Minimum B6, 5 "...
Page 549 CÓPIA NÃO CONTROLADA DIFFERENCES FROM THE A548 ARDF 2. DIFFERENCES FROM THE A548 ARDF DF64 (A663) DF61 (A548) 1-to-1 Copying Speed 40 cpm (A4/LT sideways) 35 cpm (A4/LT sideways) Capability Original Transport Speed 555 mm/s 505 mm/s Time Needed for Original 590 ms (thin original mode) 620 ms (thin original mode) Replacement (A4 sideways)
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Page 551 CÓPIA NÃO CONTROLADA SORTER STAPLER A664 CÓPIA NÃO CONTROLADA...
Page 552 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 553 CÓPIA NÃO CONTROLADA SPECIFICATIONS 1. SPECIFICATIONS Configuration: Console Number of Bins: 20 + Proof Tray Paper for Proof Tray: Size Maximum: A3, 11" x 17" Minimum: A6 lengthwise, 5 " x 8 " Weight: 52 ~ 157 g/m ,14 ~ 42 lb Capacity: Proof Tray - 250 sheets (80 g/m 20 lb)
Page 554 CÓPIA NÃO CONTROLADA SPECIFICATIONS Staple Replenishment: Cartridge refill (5,000 pieces/cartridge) 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: 566 x 583 x 978 mm (W x D x H) Weight: Approximately 48 kg...
Page 555 CÓPIA NÃO CONTROLADA COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT A664V501.wmf 1. Proof Tray 7. Staple Unit 2. Proof Exit Rollers 8. Grip Assembly 3. Proof Transport Rollers 9. Helical Wheels 4. Turn Gate 10. Jogger Plate 5. Sorter Transport Rollers 11.
Page 556 CÓPIA NÃO CONTROLADA COMPONENT LAYOUT 2.2 DRIVE LAYOUT A664V502.wmf 1. Main Motor 9. Wheel Drive Belts 2. Main Drive Belt 10. Grip Drive Belt 3. Proof Drive Belt 11. Jogger Motor 4. Sorter Drive Belt 12. Staple Unit Drive Motor 5.
Page 557 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTION 3. ELECTRICAL COMPONENT DESCRIPTION Please refer to the electrical component layout on the reverse side of the point-to-point diagram for symbol and index number reference. Symbol Name Function Index No. Motors Main Drives the paper transport rollers. Stapler Feeds the staples and drives the stapler hammer.
Page 558 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTION Symbol Name Function Index No. Solenoids Turn Gate Opens and closes the turn gate to direct the SOL1 copies into either the proof tray or the bins. Grip Opens and closes the grip arms to grip the SOL2 copies on the bins.
Page 559 CÓPIA NÃO CONTROLADA BASIC OPERATION 4. BASIC OPERATION 4.1 NORMAL (PROOF MODE) AND SORT/STACK MODE A664D500.wmf Copies exiting the copier pass through the entrance guide plates to the turn gate section. The turn gate [A] will send copies either to the proof tray or to the bins, depending on the mode.
Page 560 CÓPIA NÃO CONTROLADA BASIC OPERATION – Sort mode (from the turn gate section to the bins) – A664D501.wmf In this mode, the turn gate solenoid stays off to keep the turn gate [A] at the upper position. The main motor turns clockwise to rotate the sorter transport rollers [B] and the exit motor rotates the exit rollers [C].
Page 561 CÓPIA NÃO CONTROLADA BASIC OPERATION – Stack mode (from the turn gate section to the bins) – A664D501-2.wmf As with sort mode, the turn gate solenoid stays off and the turn gate [A] stays up when the key is pressed. The main motor turns clockwise to rotate the sorter transport rollers [B] and the exit motor rotates the exit rollers [C].
Page 562 CÓPIA NÃO CONTROLADA BASIC OPERATION 4.2 STAPLE MODE [Fig. 1] A664D502.img [Fig. 2] A664D503.img [Fig. 3] A664D504.img When the final set of copies is jogged [Fig. 1], the stapler unit staples the stacked copies as follows: The grip arms move inside the front side plate and catch the paper. The bin rear plate is turned so as to be flat with the sorter bin.
Page 563 CÓPIA NÃO CONTROLADA BASIC OPERATION [Fig. 4] A664D505.img [Fig. 5] A664D506.img The grip assembly brings the stapled copies back to the bin and the bin rear plate returns to the original position. The grip assembly releases the copies and returns to outside the front side plate so as not to disturb the bin movement [Fig.
Page 564 CÓPIA NÃO CONTROLADA TURN GATE 5. TURN GATE A664D507.wmf A664D508.wmf The turn gate [A] sends copies to the proof tray or the sorter bins depending on the mode. In the proof mode, the turn gate solenoid [B] turns on and the main motor [C] turns clockwise when the key is pressed.
Page 565 CÓPIA NÃO CONTROLADA BIN DRIVE MECHANISM 6. BIN DRIVE MECHANISM A664D509.wmf A664D510.wmf The bin drive mechanism moves the bins up and down to receive copies. The main components in this mechanism are the bin drive motor [A], the two helical wheels [B], the wheel sensor [C], and the bins themselves [D]. There are four pins on each bin.
Page 566 CÓPIA NÃO CONTROLADA BIN HOME POSITION 7. BIN HOME POSITION A664D511.wmf A664D512.wmf The bin home position sensor [A] and the wheel sensor [B] ensure that the sorter exit roller is between the upper guide plate [C] and the 1st bin [D] when all the bins are at the home position.
Page 567 CÓPIA NÃO CONTROLADA JOGGER 8. JOGGER Copier Main Motor Bin Jam Sensor 300 ms Jogger Motor A664D514.wmf A664D513.wmf • NOTE: The bin jam detector contains two LED/phototransistor pairs. • To detect jams, light from an LED above the bins passes through the slots in the bins to a phototransistor below the bins.
Page 568 CÓPIA NÃO CONTROLADA JOGGER Fig. 1 A664D515.wmf Normally all rollers in the sorter stapler transport the paper at a speed of 360 mm/s. To have enough paper jogging time, the sorter exit motor [A] rotation speed changes as follows to transport the paper quickly and to stack the paper smoothly into the bins.
Page 569 CÓPIA NÃO CONTROLADA BIN REAR PLATE DRIVE 9. BIN REAR PLATE DRIVE A664D516.wmf The bin rear plates [A] basically stand up as shown (top diagram). They are lowered only during stapling as shown (bottom diagram). In staple mode, when all copies have been jogged by the jogger plate, the bin rear plate drive motor [B] rotates gear [C].
Page 570 CÓPIA NÃO CONTROLADA GRIP ASSEMBLY 10. GRIP ASSEMBLY A664D517.wmf Staple Unit Drive O F F Motor Grip Arm Positioning O F F Solenoid Grip Solenoid O F F Bin Rear Plate O F F Drive Motor A664D518.wmf The grip assembly works as follows: When the stapler unit reaches the stapling position, the grip arm positioning solenoid [A] activates and the plunger is pulled in to move the grip arms [B] towards the rear of the machine.
Page 571 CÓPIA NÃO CONTROLADA GRIP ASSEMBLY A664D519.wmf Bin Rear Plate O F F Drive Motor Grip Motor O F F – Staple Motor O F F Grip Solenoid O F F – Grip Arm Positioning O F F Solenoid – A664D520.wmf After the bin rear plate drive motor lowers the bin rear plate, the grip motor [A] turns clockwise (white arrow) until the gripper [B] carries the paper to the stapling position.
Page 572 CÓPIA NÃO CONTROLADA STAPLER UNIT 11. STAPLER UNIT 11.1 STAPLER UNIT DRIVE MECHANISM A664D529.wmf The stapler unit moves from the home position (top slant position) towards the rear of the machine in order to change the stapling position. The stapler unit HP sensor [A] activates when the stapler unit is in the home position.
Page 573 CÓPIA NÃO CONTROLADA STAPLER UNIT 11.2 STAPLER A664D521.wmf A664D522.wmf The stapler motor [A] drives the staple sheet drive belt. The staple sheets are fed under the hammer [B]. The stapler motor drives the staple hammer via gears [C] and two eccentric cams [D].
Page 574 CÓPIA NÃO CONTROLADA STAPLER UNIT – Conditions in which Stapling is Disabled – 1. Under the following conditions, the staple mode is disabled when the staple key on the operation panel is pressed. • If there is paper in a bin before the main switch is turned on. •...
Page 575 CÓPIA NÃO CONTROLADA STAPLER UNIT 11.3 STAPLER UNIT PULL-OUT MECHANISM A664D525.wmf For easy staple cartridge replenishment, the stapler unit can be pulled out to the front. When pulling out the R3 release grip [A] , the stopper is released and the staple unit can be pulled out (to the "staple unit pulled-out" position). At this position, the stopper arm [B] locks the stapler unit by dropping the arm to the edge of bracket [C].
Page 576 CÓPIA NÃO CONTROLADA JAM DETECTION 12. JAM DETECTION Copier Exit Sensor (700 ms) 280 pls Entrance ON Check Sensor Proof Exit Sensor Bin Jam Sensor 1 pulse ¢ 3.61 ms This is the jam detection timing for the 1st bin. Timing depends on the bins used.
Page 577 CÓPIA NÃO CONTROLADA TIMING CHARTS 13. TIMING CHARTS 13.1 SORTER/STAPLER TIMING CHART (PROOF MODE) Signal Timing Chart 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 A664D527.wmf 3-25 A207/A208/A211...
Page 578 CÓPIA NÃO CONTROLADA TIMING CHARTS 13.2 SORTER/STAPLER TIMING CHART (STAPLE MODE) Signal Timing Chart Copier Main Motor ON 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...
Page 579 CÓPIA NÃO CONTROLADA SERVICE TABLES (MAIN CONTROL BOARD) 14. SERVICE TABLES (MAIN CONTROL BOARD) 14.1 DIP SWITCHES Dip Switch 100 0: OFF 1: ON Function Standard setting — — Raises all bins to the top position Free run Dip Switch 101 Vertical Staple Position Adjustment Dip Switch 102 Horizontal Staple Position Adjustment...
Page 580 CÓPIA NÃO CONTROLADA SERVICE TABLES (MAIN CONTROL BOARD) 14.2 TEST POINTS Number Function TP100 TP101 + 5 V 14.3 FUSES FUSES Rated Current and Voltage FUSE100 250 V T5A A207/A208/A211 3-28 CÓPIA NÃO CONTROLADA...
Page 581 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15. REPLACEMENT AND ADJUSTMENT 15.1 EXTERIOR COVER REMOVAL – Front – Remove the covers in the following order. A664R500.wmf A664R501.wmf 1. Remove the proof tray [A] (4 screws). 2. Open the front door. 3. Remove the front inner cover [B] (3 screws). 4.
Page 582 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Rear – A664R502.wmf 1. Remove the rear cover [A] (6 screws). 2. Remove the bottom plate [B] (2 screws and 1 hook). A207/A208/A211 3-30 CÓPIA NÃO CONTROLADA...
Page 583 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.2 STAPLER REMOVAL AND REINSTALLATION A664R503.wmf A664R504.wmf 1. Return the stapler unit [A] to the home position by pulling out the stapler unit. 2. Pull out the R3 release lever [B] and pull out the stapler unit. 3.
Page 584 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.3 JOGGER PLATE REMOVAL AND INSTALLATION A664R505.wmf A664R506.wmf – Removal – 1. Remove the proof tray. (Refer to Exterior Cover Removal.) 2. Release the spring [A] of the upper jogger holder [B], then pull out the jogger plate [C].
Page 585 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.4 BINS – Removal – A664R507.wmf A664R508.wmf 1. Remove the rear cover. 2. Raise all bins to the highest position by turning on DIP SW100-1 on the sorter main PCB, then turn off the main switch of the copier. 3.
Page 586 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT A664R509.wmf A664R510.wmf 6. Remove the top guide by releasing the pins [A] and [B] from cut-outs [C] and [D] at the end of the bin guide slots. Then remove the pins [E] and [F] from cut-outs [G] and [H].
Page 587 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Installation – A664R511.wmf A664R512.wmf 1. While holding the bin rear plate [A] straight, insert rear right guide pin [B] into the slot [C], then lower the rear guide pin to the corner [D]. 2.
Page 588 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT A664R513.wmf 4. Manually rotate the helical wheel drive belt [A] and lower the bin. NOTE: Before installing the next bin, rotate the helical wheels only once. Otherwise, the distance between the guide pins [B] will become uneven and the bins will tilt.
Page 589 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.5 MAIN MOTOR REMOVAL A664R515.wmf 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. 3-37 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 590 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.6 GRIP ASSEMBLY REMOVAL, AND GRIP SOLENOID, AND GRIP POSITIONING SOLENOID ADJUSTMENT A664R517.wmf A664R518.wmf – Grip assembly removal – 1. Open the front cover then remove the front inner cover. (Refer to Exterior Cover Removal.) 2.
Page 591 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.7 MAIN CONTROL BOARD REPLACEMENT A664R520.wmf 1. Remove the rear cover (refer to Exterior Cover Removal), then disconnect all connectors (15 connectors and 1 fiber optics connector). 2. Remove the main control board [A] (6 studs). 3.
Page 592 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.8 GRIP MOTOR REMOVAL A664R519.wmf 1. Remove the grip assembly. 2. Remove the grip motor [A] (4 screws and 2 Allen screws). A207/A208/A211 3-40 CÓPIA NÃO CONTROLADA...
Page 593 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 15.9 HELICAL WHEELS – Removal – Before removing the helical wheels, remove all bins and all exterior covers. (Refer to Exterior Cover and Bin Removal.) – Front Helical Wheel – A664R524.wmf A664R525.wmf A664R526.wmf 1. Remove the bracket [A] (4 screws). 2.
Page 594 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Rear Long Helical Wheel – A664R527.wmf A664R528.wmf 1. Remove the 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].
Page 595 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Installation – NOTE: After installing the helical wheels, perform the helical wheel alignment, which is explained later. – Rear Long Helical Wheel – A664R533.wmf 0.4 mm A664R534.wmf 1. Place the bearing [A] over the stud on the bottom plate. 2.
Page 596 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Front Helical Wheel – A664R536.wmf A664R535.wmf A664R537.wmf 1. Place the bearing [A] over the stud [B] on the bottom plate then thread timing belt-918XL [C] and timing belt-300XL [D] around the pulley. 2. Place the pulley [E] on the bearing. The direction of the pulley should be as shown in the illustration.
Page 597 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT – Alignment of the 2 Helical Wheels – A664R538.wmf A664R539.img G = 22.5 ± 0.5 mm F = 1.7 ± 0.5 mm Front Rear A664R540.wmf 1. Check that all belts are set correctly. 2. Align all screw holes [A] at the middle of the helical wheels at the center of the bin guide slots [B], as shown.
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Page 599 CÓPIA NÃO CONTROLADA SORTER STAPLER A658 CÓPIA NÃO CONTROLADA...
Page 600 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 601 CÓPIA NÃO CONTROLADA SPECIFICATIONS 1. SPECIFICATIONS Paper Size for Bins: Sort/Stack Modes: Maximum: A3, 11 x 17" Minimum: B5, 8 x 11" Paper Weight for Bins: Sorting: 52 ~ 157 g/m (14 ~ 42 lb) Stacking: 52 ~ 157 g/m (14 ~ 42 lb) Stapling: 52 ~ 157 g/m (14 ~ 42 lb)
Page 602 CÓPIA NÃO CONTROLADA COMPONENT LAYOUT 2. COMPONENT LAYOUT 2.1 MECHANICAL COMPONENT LAYOUT A658V501.wmf 1. Helical Wheels 2. Jogger Plate 3. Grip Assembly 4. Transport Rollers 5. Staple Unit 6. Bins 7. Proof Tray A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 603 CÓPIA NÃO CONTROLADA COMPONENT LAYOUT 2.2 DRIVE LAYOUT A658V502.wmf 1. Jogger Drive Belt 5. Transport Motor 2. Transport Roller 6. Bin Drive Motor 3. Wheel Drive Belts 7. Jogger Motor 4. Helical Wheels 8. Jogger Plate A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 604 CÓPIA NÃO CONTROLADA COMPONENT LAYOUT 2.3 ELECTRICAL COMPONENT DESCRIPTION Refer to the electrical component layout on the reverse side of the Point to Point Diagram (on waterproof paper). Symbol Name Function Index No. Motors Main Drive Drives the transport roller Jogger Drives the jogger plate to square the copies Bin Drive...
Page 605 CÓPIA NÃO CONTROLADA BASIC OPERATION 3. BASIC OPERATION 3.1 NORMAL MODE AND SORT/STACK MODE A658D500.wmf Copies exiting the copier pass through the entrance guide plate [A]. The transport roller will send copies either to the proof tray or to each bin, depending on the selected mode.
Page 606 CÓPIA NÃO CONTROLADA BASIC OPERATION The first copy of the second original is delivered to the final bin that was used for the first original, then the final bin descends one step. The bins descend each time a copy of the second original is delivered. The direction of motion of the bins alternates for each page of the original until the copy run is finished.
Page 607 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.2 STAPLE MODE A658D502.wmf A658D503.wmf The stapler is only available in sort mode. When the jogger plate has squared the final set of copies, the grip arms [A] move inside the front side frame and catch the paper. The grip assembly brings the copies into the stapler [B], and the stapler staples the copies.
Page 608 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.3 BIN DRIVE MECHANISM A658D504.wmf The bin drive mechanism moves the bins up and down to receive copies. There are four pins on each bin. Two pins fit into the slots [A] in both the front and rear side frames;...
Page 609 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.4 BIN HOME POSITION A658D505.wmf The bin home position sensor [A] ensures that the proof tray is lower than the transport roller when the bins are in the home position. When the main switch is turned on, the sorter stapler initializes itself to check whether the component parts work or not.
Page 610 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.5 JOGGER MECHANISM A658D506.wmf The jogger motor [A] drives the jogger plate [B] through the timing belts [C]. The jogger is at home position when the actuator on the jogger plate goes into the jogger home position sensor [D]. At standby, the jogger plate is at the home position.
Page 611 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.6 GRIP ASSEMBLY A658D507.wmf A658D508.wmf A658D509.wmf The grip assembly consists of the grip motor [A], the timing belt [B], the drive gear [C], the grip home position sensor [D], and the cam gear [E]. The grip motor drives the cam gear through the timing belt and drive gear. Cam gear rotation drives the mechanism that catches the copies and moves the grip arm unit [F].
Page 612 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.7 STAPLER UNIT A658D510.wmf The stapler motor [A] drives the staple hammer [B] using the gears [C] and the eccentric cam [D]. The roller [E] feeds the staple sheets under the hammer. When the aligned copies are brought to the staple position by the grip unit, the stapler motor starts rotating and the copies are stapled.
Page 613 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.8 STAPLER SWITCH A658D511.wmf The stapler switch [A] below the grip assembly cuts the dc +24 V supply to the stapler. In proof mode, all bins lower and push the lever [B]. This opens the stapler switch so that the signal to the stapler is cut. In sort and staple modes, all bins are advanced and the switch is closed so that the signal can be supplied to the stapler.
Page 614 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.9 PAPER FEED AND MISFEED DETECTION TIMING – Proof Mode – A4 sideways, 5 copies, 150 mm/s A658D512.wmf *1: The value of the low speed depends on the copier. – Sorter Mode – A4 sideways, two copies a of two-page original, 150 mm/s A658D513.wmf *1: The start times of the bin drive and the jogger motors depend on the paper size as shown in the following table.
Page 615 CÓPIA NÃO CONTROLADA BASIC OPERATION – Staple Mode – A4 sideways, two copies of a two-page original, after sorting, 150 mm/s A658D514.wmf 4-15 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 616 CÓPIA NÃO CONTROLADA BASIC OPERATION 3.10 JAM DETECTION – Paper Jam – A4 sideways A658D515.wmf J1: The sorter entrance sensor does not turn on within 2 s after the fusing exit sensor has turned on. J2: The fusing exit sensor does not turn off within 11.4 s after the sorter entrance sensor has turned on.
Page 617 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 4. REPLACEMENT AND ADJUSTMENT 4.1 EXTERIOR COVER REMOVAL A658R506.wmf 4.1.1 Front Cover 1. Remove the front cover [A] (2 screws). 4.1.2 Rear Cover 1. Remove the rear cover [B] (3 screws). 4.1.3 Top Cover 1.
Page 618 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 4.2 STAPLER UNIT REMOVAL A658R500.wmf 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). A207/A208/A211 4-18 CÓPIA NÃO CONTROLADA...
Page 619 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 4.3 GRIP ARM REPLACEMENT A658R501.wmf A658R502.wmf 1. Remove the front cover. (See Exterior Cover Removal.) 2. Remove the grip assembly [A] (4 screws, 2 connectors, and 1 grounding wire). 3. Remove the spring [B] and remove the slider [C]. 4.
Page 620 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 4.4 BIN REMOVAL A658R503.wmf A658R504.wmf 1. Remove the front, rear, and top covers. (See Exterior Cover Removal.) 2. Remove the upper stay bracket [A] (4 screws and 1 connector). 3. Loosen the two screws [B], then remove the timing belt [C]. 4.
Page 621 CÓPIA NÃO CONTROLADA REPLACEMENT AND ADJUSTMENT 4.5 TRANSPORT MOTOR REMOVAL A658R505.wmf 1. Remove the 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). 4-21 A207/A208/A211 CÓPIA NÃO CONTROLADA...
Page 622 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 623 CÓPIA NÃO CONTROLADA A212/A214 Service Manual – Insert Version – The A212 copier is based on the A161 copier. The A214 copier is based on the A162 copier. Only the differences from the A161/A162 copier are described in the following pages. Refer to the A161/A162 copier service manual for more information.
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Page 625 CÓPIA NÃO CONTROLADA DIFFERENCES BETWEEN THE A212/A214 AND A161/A162 The models A212/A214 are based on the A161/A162 series machines. The models A204/A206/A207/A208/A210/A211 were based on the A153/A156/ A157/A160 series machines and all differences between these two series are also included in the A212/A214 units. The following table lists the basic differences between the A212/A214 and A161/A162 series machines.
Page 626 CÓPIA NÃO CONTROLADA (Section to refer to in (A153/A156/A157/ (A212/A214) A160/A161/A162) the Service Manual) DRUM Drum All modifications indicated for the A204/A206/A207/A208/A210 /A211 series are applicable to the new A212/A214 units OPTICS Toner Shield Glass A toner shield glass and a green As in the A204/A206/A207/ filter is installed above the OPC A208/A21 /A211 series the toner...
Page 627 CÓPIA NÃO CONTROLADA Item (Section to refer to in (A153/A156/A157/ (A212/A214) the Service Manual) A160/A161/A162) PAPER FEED AND REGISTRATION Paper Feed System A157/A160/A161/A162 Corner A212/A214 Corner separation separation system system Pg. 2-77 Pg. 5-20 Paper Tray A157/A160/A161/A162 paper A212/A214 paper tray capacity tray capacity 250 sheets 500 sheets Pg.
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Page 629 CÓPIA NÃO CONTROLADA A212/A214 COPIER CÓPIA NÃO CONTROLADA...
Page 630 CÓPIA NÃO CONTROLADA CÓPIA NÃO CONTROLADA...
Page 631 CÓPIA NÃO CONTROLADA 1. SPECIFICATIONS NOTE: Only items marked with are different from A161 and A162 copiers. Configuration: Desktop Copy Process: Dry electrostatic transfer system Originals: Sheet/Book Original Size: Maximum: A3/11" x 17" Copy Paper Size: Maximum: A3/11" x 17" (Paper trays) Minimum: A5/8 "...
Page 632 CÓPIA NÃO CONTROLADA SPECIFICATIONS Power Source: 120 V/60 Hz: More than 12 A (for North America) 220 V ~ 240 V/50 Hz: More than 7 A (for Europe) 220 V/50 Hz: More than 7 A (for Asia) 110 V/60 Hz: More than 14 A (for Taiwan) 220 V/60 Hz: More than 7 A (for Saudi Arabia, Philippines)
Page 633 CÓPIA NÃO CONTROLADA Dimensions: Width Depth Height A212 copier 900 mm (35.5") 655 mm (25.8") 626 mm (24.7") A214 copier 1,128 mm (44.5") 655 mm (25.8") 626 mm (24.7") Measurement Conditions 1) With by-pass feed table closed 2) With platen cover and copy tray attached 3) With LCT cover closed Weight: Weight...
Page 634 CÓPIA NÃO CONTROLADA SPECIFICATIONS Duplex Tray Capacity 50 sheets (30 sheets for A3/11"x17" [A214]: 81 ~ 105 g/m , 21.5 ~ 27.9 lb paper) Toner Replenishment: Cartridge exchange (415 g/cartridge) • Optional Equipment Platen cover (except for A212 machines with (Sales items): destination code 29) •...
Page 635 CÓPIA NÃO CONTROLADA 2. MACHINE CONFIGURATION 2.1 COPIER – A212 copier – Two 500-sheet trays A212V500.wmf *: Only for machines with destination code 29. – A214 copier – A 500-sheet tray A duplex tray A 1000-sheet large capacity tray A212V501.wmf A212/A214 CÓPIA NÃO CONTROLADA...
Page 636 CÓPIA NÃO CONTROLADA MACHINE CONFIGURATION 2.2 OPTIONAL EQUIPMENT 500 X 3 (A549) *: Except for machines with A212 destination code 29. A212/A214 CÓPIA NÃO CONTROLADA...
Page 637 CÓPIA NÃO CONTROLADA MEMO A212/A214 CÓPIA NÃO CONTROLADA...
Page 638 CÓPIA NÃO CONTROLADA MECHANICAL COMPONENT LAYOUT 3. MECHANICAL COMPONENT LAYOUT – A214 copier – NOTE: The paper feed area has been changed. 27 26 25 A212V503.wmf NOTE: The A212 copier is the same as the A214 copier except that the A212 does not have a duplex tray or an LCT.
Page 639 CÓPIA NÃO CONTROLADA 1. 3rd Mirror 20. Separation Roller 2. 2nd Mirror 21. Large Capacity Tray 3. 1st Mirror 22. Vertical Transport Rollers 4. Exposure Lamp 23. Paper Feed Roller 5. Lens 24. Friction Pad 6. Quenching Lamp 25. Duplex Friction Roller 7.
Page 640 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS 4. ELECTRICAL COMPONENT DESCRIPTIONS Refer to the electrical component layout and the point to point diagram on the waterproof paper in the pocket for symbols and index numbers. Symbol Name Function Index No. Printed Circuit Boards Main Control Controls all copier functions both directly or PCB1...
Page 641 CÓPIA NÃO CONTROLADA Symbol Name Function Index No. Sensors By-pass Feed Paper Informs the CPU what width paper is in the Width by-pass feed table. By-pass Feed Paper End Informs the CPU that there is no paper in the by-pass tray. Upper Tray Paper End Informs the CPU when the upper paper (A212 machine only)
Page 642 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Toner End Instructs the CPU to add toner to the toner supply unit, and detects toner end conditions. Transfer Belt Contact HP Informs the CPU of the current position of both the transfer belt unit and the drum charge roller unit.
Page 643 CÓPIA NÃO CONTROLADA Symbol Name Function Index No. LCT Cover-1 Detects whether the LCT cover is open or (A214 machine only) not. LCT Cover-2 Cuts the dc power line of the LCT lift motor. (A214 machine only) Main Supplies power to the copier. Front Cover Safety Cuts the ac power line and detects whether the front door is open or not.
Page 644 CÓPIA NÃO CONTROLADA ELECTRICAL COMPONENT DESCRIPTIONS Symbol Name Function Index No. Secondary Fusing Provides heat to both ends of the hot roller. Modified - see the "Fusing" section for details. Pre-transfer Reduces the charge remaining on the drum surface before transfer. Quenching Neutralizes any charge remaining on the drum surface after cleaning.
Page 645 CÓPIA NÃO CONTROLADA Symbol Name Function Index No. Key (option) Used for control of authorized use. The copier will not operate until it is installed. Others Circuit Breaker (220 ~ Provides back-up high current protection 240 V machines only) for electrical components. Transformer (220 ~ 240 Steps down the wall voltage to 100 Vac.
Page 646 CÓPIA NÃO CONTROLADA PROCESS CONTROL 5. PROCESS CONTROL Refer to the A204/A206/A207/A208/A210/A211 service manual for detailed information. 5.1 TEMPERATURE CORRECTION A212D500.wmf Temperature correction has changed, as explained below. Also, the machine no longer performs drum rotation time correction. The new drum charge roller needs only about half the correction voltage that was needed in the base copier.
Page 647 CÓPIA NÃO CONTROLADA 6. DRUM NOTE: The drum in this machine is the same as the A204/A206/A207/A208/ A210/A211 copiers. Please refer to the A204/A206/A207/A208/A210/ A211 manual for details. 5-17 A212/A214 CÓPIA NÃO CONTROLADA...
Page 648 CÓPIA NÃO CONTROLADA OPTICS 7. OPTICS 7.1 OVERVIEW 7.1.1 Toner Shield Glass The shield glass by the green filter above the drum has been removed (it is no longer needed). 7.2 SCANNER DRIVE The returning speed of the first scanner has changed to 1,000 (mm/s). A212/A214 5-18 CÓPIA NÃO CONTROLADA...
Page 649 CÓPIA NÃO CONTROLADA 8. DEVELOPMENT CLUTCH ON/OFF TIMING The development clutch ON/OFF timing has been changed to prolong the life of the developer. The life of the developer has been increased from 100 k to 120 k. Development Clutch ON Time (s) Reducation A161/A162 copiers A212/A214 copiers...
Page 650 CÓPIA NÃO CONTROLADA PAPER FEED AND REGISTRATION 9. PAPER FEED AND REGISTRATION 9.1 OVERVIEW A212D503.wmf The paper feed station uses a paper tray [A] which can hold 500 sheets. The paper tray uses semicircular feed rollers [B] and a corner separator. The semicircular feed rollers make one rotation to drive the top sheet of the paper stack to the relay rollers [C].
Page 651 CÓPIA NÃO CONTROLADA 9.2 PAPER TRAY FEED 9.2.1 Paper Lift Mechanism A212D501.wmf The capacity of this tray is greater than usual for a corner separator type. Because of this, there are two springs to lift the bottom plate. As the tray is pushed into the machine, shutter [A] under the tray pushes against projection [B].
Page 652 CÓPIA NÃO CONTROLADA PAPER FEED AND REGISTRATION A212D504.wmf The paper tray capacity has been increased from 250 to 500 sheets and the paper lift mechanism differs from former one. Force is applied to the bottom plate by the main lift spring and the secondary lift spring, depending on the amount of paper remaining in the tray.
Page 653 CÓPIA NÃO CONTROLADA 9.3 Corner Separator Over Rising Prevention Mechanism A212D505.wmf A212D506.wmf The bottom plate stopper [A] prevents the corner separator from rising too high. When the tip of bottom plate stopper touches the bottom plate by the weight of stopper itself, point [B] on the bottom plate stopper contacts [C] on the corner separator.
Page 654 CÓPIA NÃO CONTROLADA PAPER FEED AND REGISTRATION 9.4 Corner Separator Stopper Mechanism A212D502.wmf The corner separator stopper prevents the corner separator from dislocation when the tray holds a lot of paper. When the paper tray is pushed into the machine, the stopper holder [A] slides to press the corner separator stopper [B] down.
Page 655 CÓPIA NÃO CONTROLADA 10. INSTALLATION 10.1 COPIER ACCESSORY CHECK Check the accessories against the following list: Description Q’ty 1. Paper Size Decal.............. 1 2. Symbol Explanation Decal..........1 3. Optional Margin Adjustment Function Decal ....1 4. Combine Originals Explanation Decal......1 5.
Page 656 CÓPIA NÃO CONTROLADA INSTALLATION 10.2 COPIER INSTALLATION PROCEDURE CAUTION Rating Voltage for Peripherals Make sure to plug the cables into the correct sockets. A212I500.wmf A212/A214 5-26 CÓPIA NÃO CONTROLADA...
Page 657 CÓPIA NÃO CONTROLADA A212I514.wmf - A214 copier - A212I501.wmf NOTE: 1) Never lift the machine by holding the LCT, or the LCT will break. 2) Keep the shipping retainers after installation. They will be reused if the machine is moved to another location. 3) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
Page 658 CÓPIA NÃO CONTROLADA INSTALLATION - A214 copier - A212I502.wmf 5. A214 copier only: 1) Pull out the duplex tray [A] and remove the strips of tape [B]. 2) Remove the guide roller stopper [C] and a sheet of paper [D]. 3) Open the upper duplex guide plate [E] and remove the strips of tape [F].
Page 659 CÓPIA NÃO CONTROLADA A212I515.wmf A212I503.wmf 6. Open the front cover and swing out the toner bottle holder [A]. 7. Remove the strips of tape [B]. 8. Remove the switch actuator lock bracket [C] as shown. 9. Turn the "A1" lever [D] counterclockwise to lower the transfer belt unit. Then remove the cushion sheet [E].
Page 660 CÓPIA NÃO CONTROLADA INSTALLATION A212I504.wmf A212I505.wmf 12. Remove the knob screw [A]. Swing out the bottle holder [B] and pull down the lock lever [C]. Then slide out the bottle holder assembly [D] and swing out the bottle holder assembly [D]. 14.
Page 661 CÓPIA NÃO CONTROLADA A212I506.wmf A212I507.wmf 16. Disconnect the connector [A] and separate the toner supply unit [B] from the development unit (2 screws). 17. Pour about half a pack of developer [C] into the development unit. Then rotate the outer gear [D] as shown to distribute the developer evenly. Then pour in all the remaining developer and rotate the gear again.
Page 662 CÓPIA NÃO CONTROLADA INSTALLATION A212I508.wmf IMPORTANT: Do not swing the bottle holder fully into the machine before step 20. 20. Swing in the bottle holder assembly [A] so that the toner bottle holder [B] and the slide rail [C] are aligned properly. 21.
Page 663 CÓPIA NÃO CONTROLADA A212I509.wmf 25. Enter SP mode as follows: 1) Press the key. 2) Enter "107" using the numeric keys. 3) Hold down the key for more than 3 seconds. NOTE: 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.
Page 664 CÓPIA NÃO CONTROLADA INSTALLATION A212I512.img A212I510.wmf A212I511.wmf 28. Pull out the paper tray and load paper into it. (The paper size and direction for each tray should be as specified by the customer.) NOTE: The side and rear fences should be properly positioned. 29.
Page 665 CÓPIA NÃO CONTROLADA A212I513.wmf 34. Install the optional platen cover [A] if necessary: 1) Install 2 stud screws [B] on the top cover as shown. 2) Position the platen cover bracket [C] on the stud screws and slide it to the left.
Page 666 CÓPIA NÃO CONTROLADA INSTALLATION 10.3 AUTO REVERSE DOCUMENT FEEDER (A663) Refer to the A204/A206/A207/A208/A210/A211 service manual for detailed information. 10.4 20-BIN SORTER STAPLER (A658) Refer to the A204/A206/A207/A208/A210/A211 service manual for detailed information. A212/A214 5-36 CÓPIA NÃO CONTROLADA...
Page 667 CÓPIA NÃO CONTROLADA SERVICE REMARKS 11. SERVICE REMARKS 11.1 PAPER FEED Only the following item is new. Always push the paper tray in gently. If the tray is slammed shut, the paper stack might go over the side fence or the corner separators, causing double feed or image skewing problems.
Page 668 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12. SERVICE PROGRAM MODE 12.1 SERVICE PROGRAM MODE TABLE 1. Items written in bold italic letters are newly added service programs. 2. Items written in bold are modified service programs from the A161/A162 copiers. 3.
Page 669 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function 2-002-xxx Drum Charge Voltage Display † 2-003 Drum Charge Voltage Adjustment (for making V patterns) 2-101-xxx Leading/Trailing Edge Erase Margin Adjustment † 2-201-xxx Development Bias Adjustments † 2-203 Development Bias Adjustment (for making V patterns) 2-206-xxx Development Bias Display †...
Page 670 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function 4-102 Lens Error Correction † 4-103 Focus Adjustment † 4-201 Auto ADS Gain Adjustment 4-202 ADS Initial Gain Display † 4-203 ADS Actual Gain Display † 4-301 APS Sensor Function Check † 4-302 Optional APS Sensor (LT version only) †...
Page 671 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function °5-501-001 PM Interval Setting † °5-501-002 PM Interval Setting (PM Alarm Mode Setting) † 5-504 Used in Japan only. Do not change the factory setting. 5-505 Used in Japan only. Do not change the factory setting. °5-507 Used in Japan only.
Page 672 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Initial Copy Counter Setting for RDS/CSS Display † This is for use with features that are available only in Japan. °7-004 However, it does show the total number of copies that have been made.
Page 673 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12.1.2 SP Mode Table Mode No. Function Settings Registration † Adjusts leading edge registration. 0 ~ 32 1-001 Default = 16 ‡ (0.5 mm per step [Range: –8.0 mm to +8.0 mm]) Paper Feed Adjusts the paper feed timing at 0 ~ 32 Timing †...
Page 674 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Fusing Adjusts the temperature of the main 170 ~ 190 Temperature fusing lamp, which heats the central area Default = 175 Adjustment of the hot roller. 1-105-001 (Main Fusing The selected temperature is displayed in Lamp) †...
Page 675 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Jogger Span Adjusts the stop position of the jogger 0 ~ 32 Adjustment side fence span of the duplex unit. Default = 16 1-902 (Side Fence) † (0.5 mm per step [Range: –8.0 mm to +8.0 mm]) A214 copier only Jogger Span...
Page 676 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Lightest ID Adjusts the development bias for manual 1: –40 V 2: ±0 V Level ID level 7. 2-201-002 Development 3: –80 V The adjustment factor set with this SP Bias 4: –120 V mode is applied to the base voltage...
Page 677 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Toner Supply Selects the toner supply ratio for TD 1: 7% Ratio sensor supply mode. 2: 15% (TD Sensor For example, if the user normally makes 3: 30% 2-208-002 Supply Mode) † copies of originals that are about 7% 4: 60% black, select the 7% setting for best...
Page 678 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Drum Reverse Adjusts the amount of the time for the 0 ~ 32 Rotation drum reverse rotation after each copy job. Default = 16 Adjustment † (about 3 mm) If paper dust remains on the drum, it may 2-812 get into the recycled toner.
Page 679 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Current Displays the current V value [%] This is the value currently being used for Display † correction. ID Correction Drum Charge Roller Development Bias Correction Voltage Correction Voltage ±0 V –40 V –80 V 3-111...
Page 680 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Forced Process Performs the 1,000-copy process control Control cycles forcibly. initial adjustment → V detection → detection → V 3-902 (pattern) adjustment This mode starts after the key is pressed. Exposure Lamp Adjusts the exposure lamp voltage 50.0 ~ 75.0 V...
Page 681 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Lens Horizontal Adjusts the lens horizontal home position 0 ~ 32 V HP Adjustment for each paper feed station. Default = 16 ‡ † (0.2 mm per step [Range: –3.2 mm to (only 4-011- +3.2 mm]) 008 is on the...
Page 682 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Auto ADS Gain Adjusts the ADS gain automatically to make the sensor output 2.7 ± 0.1 V. Adjustment Close the platen cover to prevent 4-201 external light from reaching the ADS sensor.
Page 683 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings APS 8 k/16 k Selects whether the machine can select 0: NO Detection † 8 k/16 k copy paper based on APS 1: YES (A4 versions sensor readings. only) If "YES" is selected, 8 k/16 k copy paper is selected under the following conditions: Size detected by Selected copy paper size...
Page 684 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Paper Size Set Sets the paper size for each paper tray For how to • °5-019-001 † and feed station. input the settings, see 5-019-008 section 2.7. Duplex Priority Specifies whether the copier defaults to 1: Duplex Selection duplex or single sided copies mode.
Page 685 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Image Shift This controls the left and right margin A4 version Margin width adjustment for both 1st and 2nd 0 ~ 15 Adjustment † side copies. Default = 5 SP5-107-001: Left Margin (1st side) LT version SP5-107-002: Right Margin (1st side) 0 ~ 0.60...
Page 686 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Auto Shut Off Selects the auto shut off time in NA version Time Setting † one-minute steps. 1 ~ 120 Default = 60 • The copier main switch is shut off °...
Page 687 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings User Code Deletes user code numbers. Number Clear † SP5-404-001: Deletes individual user code numbers. Enter the required user code at the • °5-407-001 numeric keys, then press key. (To see which 5-407-002 user codes are being used, use SP5-405.)
Page 688 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Free Run Mode Performs the free run SP5-802-001: Continuous free run SP5-802-002: One time free run 5-802-001 Before starting, close the platen or 5-802-002 ARDF. Press the key to start the free run.
Page 689 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings 10 key Selects whether to have a 10 key zoom 1: Size Zoom/Size function or a size magnification function. magnification • °5-909 Magnification † 2: 10 key zoom function Do not use •...
Page 690 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Sorter Use this to specify which sorter is 0: No sorter Installation † installed. 1: A557 sorter 2: A556 sorter After setting this SP mode, the copier °6-101 3: Not used main switch must be turned off and on.
Page 691 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Total Original Displays the total number of scanned Counter Display originals (DF + platen). °7-002 † The first three digits are displayed in the reduce/enlarge indicator. Hold down the " "...
Page 692 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Feed Unit Displays the total number of copies fed Counter † from each feed unit. SP Number Without Duplex With Duplex SP7-204-001 1st tray — SP7-204-002 2nd tray 1st tray SP7-204-003 3rd tray 2nd tray...
Page 693 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Total Jam Displays the total number of copy jams Counter † plus original jams (max. 4 digits). °7-501 (Copies + The first digit is displayed in the Originals) reduce/enlarge indicator. Hold down the "...
Page 694 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Main ROM Displays the main ROM version. Version Display SP7-801-001: Copier main ROM version † SP7-801-002: Paper tray unit main ROM version SP7-801-003: DF main ROM version SP7-801-004: Sorter stapler main ROM version The ROM version is displayed by a six- digit number.
Page 695 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Copy Jam Resets the total copy jam counter Counter Reset (SP7-502) and the copy jam counters for † individual locations (SP7-504). °7-807-002 (displayed as To reset the counters, press the key.
Page 696 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE Mode No. Function Settings Feed Unit Reset one of the following counters by Counter Clear † pressing the key. SP Number Without Duplex With Duplex SP7-816-001 1st tray — SP7-816-002 2nd tray 1st tray °7-816-001 SP7-816-003 3rd tray...
Page 697 CÓPIA NÃO CONTROLADA SERVICE PROGRAM MODE 12.2 UP MODE AND SP MODE CROSS REFERENCE TABLE UP Mode SP Mode Function 5-019 Paper Size Set 5-002 Feed Station Priority Selection 5-003 APS Priority Selection 6-010 Auto APS Select (DF) 5-103 Auto Tray Shift 5-013 Counter Up/Down Selection 5-017...
Page 698 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 13. PREVENTIVE MAINTENANCE SCHEDULE 13.1 PM TABLE NOTE: The amounts mentioned as the PM interval indicate the number of copies. Symbol key: C: Clean R: Replace L: Lubricate I: Inspect 120 k 240 k 360 k NOTE OPTICS Mirrors, Lens, Reflector...
Page 699 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 120 k 240 k 360 k NOTE PAPER FEED (for each paper feed station) Feed Rollers Water (Paper tray) Pick-up, Feed, Clean with water. Replace these Separation Rollers rollers and the torque limiter as a set. (LCT, By-pass feed) Separation Torque Clean with water.
Page 700 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 120 k 240 k 360 k NOTE Hot Roller Strippers DUPLEX TRAY Clutch Spring Mobil Temp 78. See Note 1. Feed Roller Bottom Plate Pad Mylars Replace if necessary OTHERS Drive Belts Replace if necessary 120 k 240 k 360 k NOTE SORTER ADAPTER (A568)
Page 701 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE NOTE Bushings Launa oil; if bushings generate noise. Helicam Wheels Grease G501; if worm gears generate noise. Bin Cam Tracks Grease G501; if bin cam tracks generate noise. 10-BIN SORTER STAPLER (A555) Transport Roller Alcohol or water Bins Alcohol or water...
Page 702 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 13.2 REGULAR PM PROCEDURE Every 120 k Every 240 k 1. Make a Copy Make a copy of an OS-A3 test chart at manual image density level 4. 2. Optics (every 120 k) 1. Clean the mirrors, lens, and reflectors with a soft cloth, cotton pad with water, or a blower brush.
Page 703 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Clean the inside of the cleaning unit and the 4. Cleaning Unit seals. (every 120 k) 2. Replace the cleaning blade. 1. Remove the old developer. 5. Development Unit (every 240 k) 2. Clean the development unit and seals. 3.
Page 704 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Remove the transfer belt and clean the used 7. Transfer Belt Unit toner tank with a blower brush or vacuum (every 120 k) cleaner. 2. Clean the transfer belt. Replace the transfer 3. Replace the transfer belt cleaning blade. belt (every 240 k).
Page 705 CÓPIA NÃO CONTROLADA PREVENTIVE MAINTENANCE SCHEDULE 1. Clean the covers. 11. Exterior (every 120 k) 12. Development Unit Perform the following SP Modes in the following (every 120 k) order. 1. SP2-214 TD Sensor Initial Setting 2. SP3-001 ID Sensor Initial Setting 3.
Page 706 CÓPIA NÃO CONTROLADA SPECIAL TOOLS AND LUBRICANTS 14. SPECIAL TOOLS AND LUBRICANTS : New or modified items Part Number Description Q’ty A153 9001 Scanner Adjustment Tool A153 9004 WIPING CLOTH (Drum Charge Roller Cloth) 5420 9516 Test Chart - OS-A3 (10 pcs/set) 5420 9507 Digital Multimeter A008 9502...
Page 707 CÓPIA NÃO CONTROLADA SC CODE DESCRIPTIONS 15. SC CODE DESCRIPTIONS Only the following SC codes have been changed or added from the base copier. E720 - Timing Sensor (Roller Drive) Output Error (A555/A658) - Definition - [B] When the roller drive/transport motor is turning, the timing sensor takes over 500 ms to change.
Page 708 CÓPIA NÃO CONTROLADA SC CODE DESCRIPTIONS E723 - Grip Home Position Sensor Output Error (A555/A658) - Definition- [C] • When the grip motor rotates forwards, 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.

Ricoh FT5535 Service Manual

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