Ricoh A156 Service Manual
  1. Manuals
  2. Brands
  3. Ricoh Manuals
  4. All in One Printer
  5. A156
  6. Service manual

Ricoh A156 Service Manual

Ricoh a156/a212... series service manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

®
®
®
A156/A212...SERIES

SERVICE MANUAL

PN: RCFM5535
RICOH GROUP COMPANIES

Advertisement

Table of Contents
loading

Related Manuals for Ricoh A156

Summary of Contents for Ricoh A156

  • Page 1: Service Manual

    ® ® ® A156/A212...SERIES SERVICE MANUAL PN: RCFM5535 RICOH GROUP COMPANIES...
  • Page 3 ® ® ® RICOH GROUP COMPANIES...
  • Page 5 Rev. 4/98 A156/A153 A160/A157 A162/A161 SERVICE TRAINING MANUAL...
  • Page 7 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 9 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 11 The Service Training 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 13: Table Of Contents

    4.1 NORMAL COPYING ..............1-10 4.2 DUPLEX COPYING ..............1-11 5. ELECTRICAL COMPONENT DESCRIPTIONS ....1-12 6. DRIVE LAYOUT ............... 1-17 6.1 ALL MODELS ................1-17 6.2 A153/A156 ................1-18 6.3 A157/A160/A161/A162 ..............1-18 2. DETAILED DESCRIPTIONS 1. PROCESS CONTROL ............2-1 1.1 OVERVIEW..................2-1 1.1.1 Copy Process around the Drum..............2-1 1.1.2 Factors Affecting Process Control ............2-4...
  • Page 14 3.4 TEMPERATURE COMPENSATION ........2-38 4. OPTICS................2-39 4.1 OVERVIEW ................2-39 4.2 SCANNER DRIVE ..............2-41 4.3 LENS DRIVE................2-41 4.4 HORIZONTAL LENS POSITIONING ........2-43 4.4.1 Original Alignment Position ..............2-43 4.4.2 Paper Size .....................2-43 4.4.3 Reproduction Ratio ................2-43 4.5 3RD SCANNER DRIVE ............2-45 A156/A160/A162...
  • Page 15 7.4 TRANSFER BELT UNIT LIFT MECHANISM ......2-65 7.5 PAPER TRANSPORTATION AND BELT DRIVE MECHANISM ................2-66 7.6 TRANSFER BELT CLEANING MECHANISM ......2-67 7.7 TRANSFER BELT UNIT RELEASE MECHANISM ....2-69 8. DRUM CLEANING ............2-70 8.1 OVERVIEW ................2-70 8.2 DRIVE MECHANISM ..............2-71 A156/A160/A162...
  • Page 16 9.2 NEW TONER AND RECYCLED TONER MIXTURE....2-75 10. QUENCHING ..............2-76 11. PAPER FEED AND REGISTRATION ......2-77 11.1 OVERVIEW ................2-77 11.2 PAPER FEED MECHANISM [A153/A156] ......2-78 11.2.1 Drive Mechanism ................2-78 11.2.2 Slip Clutch Mechanism ...............2-79 11.2.3 Separation Roller Release Mechanism ..........2-80 11.3 PAPER FEED DRIVE MECHANISM [A157/A160] ....2-81...
  • Page 17 2. COMPONENT LAYOUT............. 3-2 2.1 MECHANICAL COMPONENTS ..........3-2 2.2 ELECTRICAL COMPONENTS ..........3-3 3. ELECTRICAL COMPONENT DESCRIPTION....3-4 4. DETAILED DESCRIPTIONS ..........3-5 4.1 ORIGINAL PICK-UP MECHANISM ..........3-5 4.2 SEPARATION AND PAPER FEED MECHANISM ......3-6 4.3 FRICTION BELT DRIVE MECHANISM ........3-7 A156/A160/A162...
  • Page 18 5. PAPER TRAY UNIT A553 1. SPECIFICATIONS.............. 5-1 2. COMPONENT LAYOUT............. 5-2 2.1 MECHANICAL COMPONENT LAYOUT ........5-2 2.2 DRIVE LAYOUT................5-2 2.3 ELECTRICAL COMPONENT DESCRIPTION......5-3 3. OVERVIEW................. 5-4 4. DRIVE MECHANISM............5-5 5. PAPER FEED AND MISFEED DETECTION TIMING ..5-6 A156/A160/A162...
  • Page 19 10.2 STAPLER ERROR..............6-25 11. TIMING CHARTS ............6-26 7. SORTER STAPLER A555 1. SPECIFICATIONS ............. 7-1 2. COMPONENT LAYOUT ........... 7-3 2.1 MECHANICAL COMPONENT LAYOUT ........7-3 2.2 DRIVE LAYOUT .................7-4 2.3 ELECTRICAL COMPONENT DESCRIPTION......7-5 3. BASIC OPERATION ............7-6 A156/A160/A162...
  • Page 20 7. BIN DRIVE MECHANISM ..........8-8 8. BINS ................. 8-10 9. EXIT ROLLERS..............8-11 10. TIMING CHART.............. 8-12 9. SORTER A557 1. SPECIFICATIONS.............. 9-1 2. COMPONENT LAYOUT............. 9-2 3. ELECTRICAL COMPONENT DESCRIPTIONS ....9-3 4. BASIC OPERATION ............9-4 A156/A160/A162 viii...
  • Page 21 Rev. 7/95 5. EXIT ROLLER DRIVE MECHANISM......... 9-5 6. BIN DRIVE MECHANISM ..........9-6 7. MISFEED DETECTION ............. 9-8 A156/A160/A162...

  • Page 23: Important Safety Notices

    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. A156/A160/A162...
  • Page 24 4. When keeping used lithium batteries (from the main control boards) in order to dispose of them later, do not store more than 100 batteries (from the main control boards) per sealed box. Storing larger numbers or not sealing them apart may lead to chemical reactions and heat build-up. A156/A160/A162...
  • Page 25 Rev. 1/98 TAB INDEX OVERALL MACHINE INFORMATION SORTER A557 DETAILED SECTION DESCRIPTION AUTO REVERSE DOCUMENT FEEDER A548 PAPER TRAY UNIT A550/A549 PAPER TRAY UNIT A553 SORTER STAPLER A554 SORTER STAPLER A555 SORTER A556...

  • Page 27: Overall Machine Information

    OVERALL MACHINE INFORMATION...

  • Page 29: Specifications

    " x 5 " (sideways) Copy Paper Weight: Paper tray: 52 ~ 128 g/m , 14 ~34 lb (A153, A155, and A156 copiers) 64 ~ 90 g/m , 17 ~ 24 lb (A157, A159, and A160 copiers) By-pass: 52 ~ 157 g/m...
  • Page 30 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 31 By-pass 4.8 s 5.6 s 5.6 s 5.0 s 5.9 s 5.9 s Note: In A156, A160 and A161 copiers, the 2nd tray in the above table is called the 1st tray (see Installation - Paper Feed Station Definition). A156/A160/A162...
  • Page 32 , 21.5 ~ 27.9 lb paper) Toner Replenishment: Cartridge exchange (415 g/cartridge) Toner Yield: 17K Copies/cartridge Developer Replenishment: Type 1 (1kg bag) Developer Yield: A153/A156 @ 120K copies A157/A160 @ 100K copies A161/A162 @ 100K copies • Optional Equipment: Platen cover •...

  • Page 33: Machine Configuration

    Rev 7/95 2. MACHINE CONFIGURATION 2.1 COPIER A156/A160/A162...

  • Page 34: Optional Equipment

    Rev 7/95 2.2 OPTIONAL EQUIPMENT Only available on models FT5535, FT4527 and FT4522 ** Not for use on FT4022/4522 (A161/A162) copiers. A156/A160/A162...

  • Page 35: Mechanical Component Layout

    3. MECHANICAL COMPONENT LAYOUT – A156 copier – 27 26 25 NOTE: The A153 copier is the same as the A156 copier except that the A153 does not have a duplex tray or an LCT. A156/A160/A162...
  • Page 36 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 A157 and A161 do not have a duplex tray or an LCT. A156/A160/A162...
  • Page 37 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. Lens 25. Duplex Friction Roller 6.

  • Page 38: Paper Path

    Rev. 7/95 4. PAPER PATH 4.1 NORMAL COPYING – A156 copier – –A160/A162 copier – A156/A160/A162 1-10...

  • Page 39: Duplex Copying

    Rev. 7/95 4.2 DUPLEX COPYING – A156 copier – – A160/A162 copier – 1-11 A156/A160/A162...

  • Page 40: Electrical Component Descriptions

    Controls the operation of the duplex tray. PCB9 (Duplex machines only) Liquid Crystal Display Controls the guidance display and displays PCB10 (A156 machines only) guidance for machine operation. LCT Interface Interfaces the LCT control signal between PCB11 (LCT machines only) the main board and the LCT.
  • Page 41 Lower Tray Upper Limit Detects the height of the paper stack in the (A153/A156 lower paper tray to stop the lower tray lift motor. machines only) LCT Lower Limit Sends a signal to the CPU to stop lowering (LCT machines only) the LCT bottom plate.
  • Page 42 Supplies power to the copier. Front Cover Safety Detects whether the front door is open and SW11 via relays cuts the ac power. Exit Cover Safety Detects whether the exit cover is open or not. SW12 (A157/A160 machines only) A156/A160/A162 1-14...
  • Page 43 (A153/ machines pick-up roller in the upper paper tray. only) Lower Tray Pick-up Controls the up/down movement of the SOL5 (A153/A156 pick-up roller in the lower paper tray. machines only) Upper Tray Controls the up-down movement of the Separation separation roller in the upper paper tray feed...
  • Page 44 Provides back-up high current protection for (220 ~ 240V electrical components. machines only) Choke Coil Removes high frequency current. (220 ~ 240V machines only) Transformer Steps down the wall voltage to 100 Vac. (220 ~ 240V machines only) A156/A160/A162 1-16...

  • Page 45: Drive Layout

    10. Registration Clutch Gear Gear 11. By-pass Feed Clutch Gear 4. Scanner Drive Motor 12. Development Drive Clutch Gear 5. Scanner Drive Pulley 13. Toner Supply Clutch Gear 6. Transfer Belt Drive Gear 7. Fusing Unit Drive Gear 1-17 A156/A160/A162...

  • Page 46: A153/A156

    Rev. 7/95 6.2 A153/A156 1. Upper Paper Feed Clutch Gear (A153 only) 2. Lower Paper Feed Clutch Gear 3. Relay Clutch Gear 6.3 A157/A160/A161/A162 1. Upper Paper Feed Clutch Gear (A157 and A161 only) 2. Lower Paper Feed Clutch Gear 3.

  • Page 47: Detailed Descriptions

    DETAILED DESCRIPTIONS...

  • Page 49: Process Control

    (OPC) drum. The charge remains on the surface of the drum because the OPC layer has a high electrical resistance in the dark. The amount of negative charge on the drum is proportional to the negative voltage applied to the drum charge roller. A156/A160/A162...
  • Page 50 The PTL illuminates the drum to remove almost all the negative charge from the exposed areas of the drum. This prevents the toner particles from being reattracted to the drum surface during paper separation and makes paper separation easier. A156/A160/A162...
  • Page 51 8. CLEANING The cleaning blade removes toner remaining on the drum after the image is transferred to the paper. 9. QUENCHING Light from the quenching lamp electrically neutralizes the charge on the drum surface. A156/A160/A162...

  • Page 52: Factors Affecting Process Control

    • Operation panel (manual ID selection and reproduction ratio) • ADS sensor • TD sensor • ID sensor • Drum charge thermistor • Paper size detectors • RAM board (drum rotation time, SP mode data, and paper size data) A156/A160/A162...

  • Page 53: Process Control Procedures

    V Detection/ID Correction - The machine uses V and V readings by the ID sensor, along with readings from the toner density sensor, to determine if the toner concentration in the developer is at the optimum level. A156/A160/A162...

  • Page 54: Drum Potential Control

    ID correction.) correction data must be reset by SP mode (forced V detection) if the drum is changed or if the ID sensor is cleaned or replaced. A156/A160/A162...
  • Page 55 This section has provided an overview of all the process control procedures done by the machine. The next few pages will explain each of these in more detail. At the end, there will be a summary. A156/A160/A162...

  • Page 56: Copy Image Control

    ID range. Table 2. Development bias control by manual ID level ID Level Development Bias +80 V ±0 V ±0 V ±0 V ±0 V ±0 V SP2-201-002 (see below) Note: The base development bias voltage is -240 Volts. A156/A160/A162...
  • Page 57 Reproduction Development Bias Ratio (%) Correction Voltage 181 ~ 200 –100 V 161 ~ 180 –80 V 142 ~ 160 –60 V 123 ~ 141 –40 V 116 ~ 122 –20 V ±0 V 51 ~ 115 –30 V A156/A160/A162...
  • Page 58 1,000 copies on p2-29.) It is kept at 2.7±0.1 volts by a gain adjustment. See the "Optics - Automatic Image Density Control System (ADS)" section for more details on how the ADS sensor measures the background and on how [V (pattern)] is corrected every 1,000 copies. A156/A160/A162 2-10...

  • Page 59: Image Density Control

    This compensates for any variations in light intensity from the LED component of the sensor or the reflectivity of the drum. The V pattern [B] is made on the OPC drum by the drum charge roller [C] and the erase lamp [D]. 2-11 A156/A160/A162...

  • Page 60: Id Correction For The

    If uncontrolled, this would cause some side effects, such as low image density or developer adhering to the copy. To prevent these side effects, ID correction is done when the V pattern is made. A156/A160/A162 2-12...
  • Page 61 The first time this happens, the correction is -40 V. If the upper limit is exceeded 100 consecutive times again later, an extra -40 V correction is applied (see the following table). There should be no need for further steps, because the toner proportion by weight will stabilize before this. 2-13 A156/A160/A162...

  • Page 62: Toner Supply Control During Copying

    TSC = Toner supply coefficient [%] = Amount of toner supplied per unit of time = 0.183 [mg/ms] (for A153, A155, and A156 copiers) = 0.133 [mg/ms] (for A157, A159, and A160 copiers) AT and TS are constant, and S depends only on paper size, but TSC is determined in different ways depending on which toner supply mode is in use.
  • Page 63 0.161 ~ 0.205 –6 x 0.0196 0.206 ~ 0.500 –8 x 0.0196 0.501 ~ The previous V TREF pattern lighter TSC [%] is then determined from V and the toner supply ratio, as TREF shown by table 8. 2-15 A156/A160/A162...
  • Page 64 The supply ratio is selected with SP2-208-002. The settings are 1 (7%), 2 (15%), 3 (30%), or 4 (60%). The default is 15%. – V TREF • at the moment that TD sensor supply mode was selected. TREF TREF • = Current TD sensor output A156/A160/A162 2-16...

  • Page 65: Toner Supply In Abnormal Sensor Conditions

    (T) is Charge Thermistor None Mode between 0 °C and 20°C Output NOTE: No indication is displayed under the "abnormal drum charge thermistor output" condition, because the machine soon recovers due to the heat inside the machine. 2-17 A156/A160/A162...

  • Page 66: Drum Potential Control

    (with all corrections included). At the same time, all the blocks of the erase lamp turn on to illuminate this charged area of the drum. A156/A160/A162 2-18...
  • Page 67 If development bias has been increased by ID correction, the V correction may be smaller in some cases to take this into account. This is shown by both the table above and the following figure. ID correction –40 V –80 V 2-19 A156/A160/A162...
  • Page 68 ID sensor cleaned or replaced. (See Service Tables - Practical SP Mode Use Tables for the correct sequence of SP modes to perform at this time). The correction is done in the same way as described above. A156/A160/A162 2-20...

  • Page 69: L Pattern Correction

    ID sensor. It has the same value as V (see Image Density Control - V and V Detection). • is the output from the ID sensor reflected from the V pattern. 2-21 A156/A160/A162...
  • Page 70 V pattern (see Image Density Control for details on this ID Correction). It is applied as shown in Table 12. Table 12 ID correction –40 V –80 V ±0 V (ID) –10 V –20 V A156/A160/A162 2-22...
  • Page 71 For example, taking the ID correction to be zero for now, if V 150%, the lamp correction will be -1V (made slightly dimmer). Using the same example, but with an ID correction of -40V, the correction will be 0 V this time. ID correction –40 V –80 V 2-23 A156/A160/A162...

  • Page 72: T/H Correction

    ID sensor patterns. See below for how the correction is determined. The T/H correction difference between the A153, A155, and A156 copiers and the A157, A159, and A160 copiers is a result of the difference in copy processing speed (200 mm/s for the A153, A155, and A156 copiers, compared with 150 mm/s for the A157, A159, and A160 copiers).
  • Page 73 Table 14. T/H Correction (Copying) - Base drum charge voltage = -1500 A153, A155, and A156 copiers Drum Charge Roller Drum Rotation Time (H) 0 ≤ H < 40 40 ≤ H < 110 110 ≤ H Temperature (T ) 37.1 ≤...

  • Page 74: Process Control During Abnormal Conditions

    Correction Correction Adjustment Adjustment Thermistor Error TD Sensor Adjustment Error Disabled TD Sensor Detection Error Error Error ID sensor adjustment error → Disabled ID Sensor If the ID sensor can be adjusted → Executed Adjustment Error Executed Error A156/A160/A162 2-26...

  • Page 75: Process Control And Sensor Detection Timing

    Dev. bias ID sensor New drum or Lamp voltage correction exp. lamp • Drum Drum charge charge (temperature) H is reset at roller voltage roller the drum Every copy correction thermistor (drum initial setting rotation time) • RAM Board 2-27 A156/A160/A162...

  • Page 76: Process Control Checks During Machine Operation

    I M A G E D E N S I T Y run if more than 10 copies C O N T R O L Affects: Development bias have been made since the Detection Toner supply clutch on time previous V detection. A156/A160/A162 2-28...
  • Page 77 I M A G E D E N S I T Y C O N T R O L TD Sensor Initial Setting Resets ID correction for the V pattern to zero (this affects development bias and exposure lamp voltage) 2-29 A156/A160/A162...

  • Page 78: Copy Image Control

    2.7 ± 0.1 V SP 3-105 D R U M P O T E N T I A L Detects the initial V C O N T R O L value for the new drum Detection A156/A160/A162 2-30...

  • Page 79: Manual Id Correction

    (ID) = ID compensation factor based on the current ID correction used for making V patterns. Correction to the drum charge voltage, selected with SP2-001. CP = Correction to the drum charge voltage for maknig V patterns, selected with SP2-003. Vexp = Exposure lamp voltage, selected with SP4-001. 2-31 A156/A160/A162...

  • Page 80: Drum

    (OPC) drum (diameter: 60 mm) is used for this model. 1. OPC Drum 5. Cleaning Blade 2. Drum Charge Roller 6. Pick-off Pawl 3. Drum Charge Roller Cleaner 7. ID Sensor 4. Drum Charge Thermistor 8. Recycled Toner Transport Coil A156/A160/A162 2-32...

  • Page 81: Drive Mechanism

    [A]. The pick-off pawls [B] are always in contact with the drum surface under a light spring pressure. They move from side to side during the copy cycle. This movement is made with a worm gear [C] and an eccentric cam gear [D]. 2-33 A156/A160/A162...

  • Page 82: Drum Charge

    The CB high voltage supply board [C] gives a constant dc voltage of –1500 V (–1300 V for the V pattern) to the drum charge roller at the charge roller terminal [D]. This gives the drum surface a negative charge of –900 V (–600 V for the V pattern). A156/A160/A162 2-34...

  • Page 83: Drum Charge Roller Drive Mechanism

    When the start key is pressed, the temperature around the drum charge roller is measured while the drum charge thermistor contacts the drum charge roller. After that, the temperature is measured while the drum charge thermistor is away from the drum charge roller. 2-35 A156/A160/A162...
  • Page 84 [A]. (The roller speed is 50 rpm for A153, A155, and A156 copiers, and 37 rpm for A157, A159, and A160 copiers.) At this time, the roller touches the cleaning pad, and this helps keep the roller clean, although a cleaning routine automatically takes place at the end of every copy cycle (see below).

  • Page 85: Drum Charge Roller Cleaning

    (and thus the interval between end-of-copy-job cleaning runs) is longer than for small volume intermittent copy runs. In this case, the copy count interval for cleaning must be reduced with SP2-901, to have the ten-second cleaning routine done more often. 2-37 A156/A160/A162...

  • Page 86: Temperature Compensation

    This heater is turned on while the copier main switch is turned off. It keeps the temperature around the drum and drum charge roller over 15°C. For this heater to operate, the power cord of the copier must be plugged in even when the main switch is turned off. A156/A160/A162 2-38...

  • Page 87: Optics

    The specifications of the lamp are as follows. Note that the A153/155/156 models are faster, so they need more light during exposure. 115V Machines 230V Machines A153/A155/A156 97V 280W 85V 280W A157/A159/A160 97V 200W...
  • Page 88 Note that the A153/155/156 models have two fans; this is because the exposure lamp is more powerful in this model, so more cooling is needed. A153/A155/A156 A157/A159/A160 Rotating temperature 45°C 40°C...

  • Page 89: Scanner Drive

    The first scanner drive speed in full size mode is: 200 (mm/s) for A153/A155/A156 copiers 150 (mm/s) for A157/A159/A160 copiers The first scanner drive speed for a selected reproduction ratio is:...

  • Page 90: Lens Drive

    Since this model has a horizontal lens drive mechanism, side-to-side registration adjustment for each feed station can be done easily using SP mode (SP4-011). A156/A160/A162 2-42...

  • Page 91: Horizontal Lens Positioning

    Therefore, the lens horizontal position has to be changed in accordance with the paper size. The diagram shows the horizontal position of the lens for three paper sizes (A, B, and C) in full size mode. 2-43 A156/A160/A162...

  • Page 92: Reproduction Ratio

    At the same time, the total focal length has to be changed to adjust the image focusing. For this focal length change, the vertical position of the 3rd scanner is also adjusted. The figure shows the vertical and horizontal position of the lens for ratios of 50, 100 and 200%. A156/A160/A162 2-44...

  • Page 93: 3Rd Scanner Drive

    [B] and the rack gear [C]. The 3rd scanner home position sensor [D] detects the 3rd scanner position for full size mode. The machine keeps track of the 3rd scanner position based on the number of motor drive pulses. 2-45 A156/A160/A162...

  • Page 94: Uneven Light Intensity Correction

    The shading plate is fixed to the lens unit. The shading plate corrects the light intensity when the lens horizontal position is shifted (from [A] to [C]). Also, two shading mylars [D] intercept any stray reflected light from outside the light path. A156/A160/A162 2-46...

  • Page 95: Original Size Detection In Platen Mode

    While the main switch is on, these sensors are active and the original size data is always sent to the main CPU. However, the main CPU checks the data only when the platen cover is opened. 2-47 A156/A160/A162...
  • Page 96 11" x 15" originals in North American models. (See FSM page 3-23) This original size detection method eliminates the necessity for a pre-scan and increases the machine’s productivity. Original size detection using the ARDF is described in the manual for the ARDF. A156/A160/A162 2-48...

  • Page 97: Automatic Image Density Control System (Ads)

    2.7 ± 0.1 V. The gain value is stored in the RAM board. If the output cannot be made to equal 2.7 ± 0.1 Volts even if the gain is adjusted as far as it will go, the machine generates a Service Call code. 2-49 A156/A160/A162...
  • Page 98 Sampling is performed on each copy. (If more than one copy is made of the same original, sampling is only done for the first copy run.) Note: There is an optional extra ADS sensor for users who have copy quality problems with certain types of red original. (See FSM page 3-24) A156/A160/A162 2-50...

  • Page 99: Erase

    The erase lamp unit consists of a row of 54 LEDs extending across the full width of the drum. In erase mode (center erase or side erase), the appropriate LEDs turn on in accordance with the modes selected by the user. 2-51 A156/A160/A162...

  • Page 100: Leading Edge And Trailing Edge Erase

    LEDs turn on in blocks. This prevents the shadow of the original side edge and the unexposed front and rear sides of the drum surface in reduction mode from being developed. This reduces toner consumption and the drum cleaning load. A156/A160/A162 2-52...

  • Page 101: Development

    The toner density sensor [F] located under the unit measures the toner concentration in the developer. A hole, fitted with a filter [G], has been made in the top of the unit to relieve air pressure and to minimize toner scattering. 2-53 A156/A160/A162...

  • Page 102: Drive Mechanism

    [E] when the toner supply clutch [F] activates. All gears on the development unit are helical gears. These gears are quieter than normal gears. The development drive shaft engages the development roller gear when the development unit is pushed in. A156/A160/A162 2-54...

  • Page 103: Cross-Mixing

    [E] move it slightly toward the rear of the unit. Part of the developer falls into the auger inlet and is transported to the front of the unit by the auger [F]. As a result of this mechanism, the developer stays level in the development unit. 2-55 A156/A160/A162...

  • Page 104: Toner Density Sensor

    As the amount of toner in the developer increases, the effect of the carrier particles decreases and the voltage applied to CN122-12 decreases. Conversely, when sensor coils increases and the voltage at CN122-12 also increases. A156/A160/A162 2-56...

  • Page 105: Development Bias Control

    The correction selected here does not affect toner supply control or pattern detection, as it is not applied when developing sensor patterns on the drum, and the bias control system is different (see Process Control for full details). 2-57 A156/A160/A162...

  • Page 106: Toner Supply

    • The chuck releases the toner bottle cap into its proper position. • The toner shutter shuts the opening as a result of the pressure of the torsion spring [K]. A156/A160/A162 2-58...

  • Page 107: Toner Supply Mechanism

    80% new toner to 20% recycled toner. For more details on toner recycling, see the Toner Recycling section. For more details on toner supply control, see the Process Control Section. 2-59 A156/A160/A162...

  • Page 108: Toner End Detection

    10 seconds.) If the toner end sensor outputs a high signal (5V), the toner end condition is canceled. The toner end sensor surface is cleaned by the movement of the spring [B] attached to the agitator shaft. A156/A160/A162 2-60...

  • Page 109: Image Transfer And Paper Separation

    This makes image transfer easier. The pre-transfer lamp turns on and off at the same time as the main motor. 2-61 A156/A160/A162...

  • Page 110: Image Transfer And Paper Separation

    The transfer belt unit consists of the following parts: [A] Transfer belt A belt (length: 334 mm for A153, A155, and A156 copiers; 244.5 mm for A157, A159, and A160 copiers) with high electrical resistance which holds a high negative electrical potential and attracts the toner from the OPC drum onto the paper.

  • Page 111: Image Transfer And Paper Separation Mechanism

    –6.5 kilovolts is applied to the transfer bias roller [I]. The negative charge attracts the positively charged toner [J] from the OPC drum. It also attracts the paper and separates the paper from the OPC drum. –1.0 ~ –6.5KV 2-63 A156/A160/A162...
  • Page 112 The positive feedback of I to the power supply board causes the voltage to increase and decrease with I so that (I remains constant. (The relationship is I = I – I A156/A160/A162 2-64...

  • Page 113: Transfer Belt Unit Lift Mechanism

    ID sensor. • To prevent a change in the OPC drum characteristics because of the influence of additives inside the rubber belt. 2-65 A156/A160/A162...

  • Page 114: Paper Transportation And Belt Drive Mechanism

    [D] as the belt turns sharply around the transfer belt drive roller. The tapered parts [E] at both sides of the drive roller [F] help keep the transfer belt [G] at the center position. A156/A160/A162 2-66...

  • Page 115: Transfer Belt Cleaning Mechanism

    The toner that is scraped off falls into the toner collection tank [B]. Collected toner must be discarded from the opening [C] at each preventive maintenance call. This toner must not be recycled, because it contains paper dust. 2-67 A156/A160/A162...
  • Page 116 (–1.0 ~ –6.5 kV). As a result of this negative charge, the negatively-charged toner is repelled and is attracted to the drum. This toner is then scraped off by the drum cleaning blade. A156/A160/A162 2-68...

  • Page 117: Transfer Belt Unit Release Mechanism

    When the transfer belt unit release lever "A1" [A] is rotated counterclockwise, the transfer belt unit [B] is released, allowing it to rotate down clockwise. This mechanism allows easy paper jam recovery and easy maintenance of the transfer belt unit. 2-69 A156/A160/A162...

  • Page 118: Drum Cleaning

    [B]. Collected toner is transported to the recycled toner transport coil [C]. To remove the toner that is accumulated at the edge of the cleaning blade, the drum turns in reverse for about 3 mm at the end of every copying job. A156/A160/A162 2-70...
  • Page 119 [A] then transmits the drive to the toner collection coil [E]. The two gears at the front end of the cleaning unit drive gear shaft are used to move the cleaning blade from side to side and to drive the recycled toner transport coil. 2-71 A156/A160/A162...

  • Page 120: Cleaning Blade Pressure Mechanism And Side-To-Side Movement

    The pin [C] at the front end of the cleaning blade holder touches the inner rim of the sinusoidal cam gear [D] which gives a side-to-side movement to the blade. This movement helps to disperse accumulated toner to prevent early blade edge deterioration. A156/A160/A162 2-72...

  • Page 121: Toner Collection Mechanism

    The recycled toner transport coil moves collected toner to the toner supply unit for recycling. (See the "Toner Recycling" section for details.) 2-73 A156/A160/A162...

  • Page 122: Toner Recycling

    [B]. This helical coil transports the collected recycled toner to the toner supply unit [C] through the opening [D]. In addition, new toner is supplied from the toner bottle [E] into the toner supply unit through the opening [F]. (Refer to the "Toner Bottle Replenishment Mechanism" section.) A156/A160/A162 2-74...

  • Page 123: New Toner And Recycled Toner Mixture

    As toner is supplied to the machine on successive occasions, the proportion of recycled toner in the development unit will approach 20% over time, until the developer is changed and the process starts again with all the toner in the development unit being new toner. 2-75 A156/A160/A162...

  • Page 124: Quenching

    The quenching lamp consists of a line of nine LEDs extending across the full width of the drum. Red LEDs are used to reduce ultra violet light which would cause light fatigue of the OPC drum. A156/A160/A162 2-76...

  • Page 125: Paper Feed And Registration

    There are two types of paper feed system: the FRR feed system and the corner separation system. • The FRR feed system is used for the A153/A155/A156 copiers, the LCT and the by-pass feed station. • The corner separation system is used for the A157/A159/A160 copiers.

  • Page 126: Paper Feed Mechanism [A153/A156]

    11.2 PAPER FEED MECHANISM [A153/A155/A156] 11.2.1 Drive Mechanism Each paper feed unit consists of a pick-up roller [A], feed roller [B], separation roller [C], relay roller [D], pick-up solenoid [E], separation solenoid [F], paper upper limit sensor [G], and paper end sensor [H].

  • Page 127: Slip Clutch Mechanism

    The input hub and the output hub slip when the rotational force exceeds the constant torque. The constant torque prevents double feeding, because it exceeds the coefficient of friction between sheets of paper. This type of slip clutch does not require lubrication. 2-79 A156/A160/A162...

  • Page 128: Separation Roller Release Mechanism

    • When paper misfeeds occur in this area, users can easily pull out paper jammed between the feed roller and the separation roller because the separation roller is away from the feed roller. A156/A160/A162 2-80...

  • Page 129: Paper Feed Drive Mechanism [A157/A160]

    [F], is a general position that is used in Japan, where people are as likely to use B size paper as A size. If paper jams or non-feed errors occur for users who mainly use B size paper, change the paper feed roller position to [E] 2-81 A156/A160/A162...

  • Page 130: Paper Lift Mechanism

    11.4 PAPER LIFT MECHANISM - A153/A155/A156 copiers - The tray switch detects when the tray is placed in the machine. When the machine detects that the paper tray is in the machine, the tray lift motor [A] rotates and the coupling gear [B] on the tray lift motor engages the pin [C] of the lift arm shaft [D].
  • Page 131 When the tray is drawn out of the machine, the tray lift motor coupling gear [E] disengages the pin [F] of the lift arm shaft, and the tray bottom plate [G] then drops under its own weight. 2-83 A156/A160/A162...
  • Page 132 Then the top sheet of paper pushes up the corner separators. This keeps the stack of paper at the correct height. When the tray is pulled out, the bottom part [G] of the tray pushes the bottom plate lift arm into the release slider. A156/A160/A162 2-84...

  • Page 133: Paper End Detection

    11.5 PAPER END DETECTION - A153/A155/A156 copiers - If there is some paper in the paper tray, the paper end feeler [A] is raised by the paper stack and paper end sensor [B] is deactivated. When the paper tray runs out of paper, the paper end feeler drops into the cutout [C] in the tray bottom plate and the paper end sensor is activated.
  • Page 134 As a result, the feeler rotates upwards. This mechanism is necessary to prevent the feeler from getting damaged by the paper tray body. A156/A160/A162 2-86...

  • Page 135: Paper Size Detection

    Using SP5-019, the first tray can be set up to accommodate one of a wider range of paper sizes. If this is done, the readings from the first tray’s switch assembly are ignored. If a different size paper is used without changing SP5-019, paper jams will result. 2-87 A156/A160/A162...

  • Page 136: Side Fence Double Stopper Mechanism [A157/A160]

    The release levers [B] have a stopper which contains teeth like those on a gear. The guide rails [C] also have teeth. When the release lever is pushed, the gear teeth release each other and the side fences can be moved. A156/A160/A162 2-88...

  • Page 137: Large Capacity Tray

    During the copy cycle, the pick-up roller is lowered to prepare for feeding the next sheet of paper. When the level of the paper stack has fallen, the LCT upper limit sensor becomes deactivated and the LCT lift motor turns on to maintain the correct level for paper feed. 2-89 A156/A160/A162...

  • Page 138: Paper Feed Mechanism

    When the LCT runs out of paper, the actuator [B] pivots into the LCT paper end sensor. Then the LCT lift motor starts to rotate in reverse to lower the LCT bottom plate. When the LCT lower limit sensor [C] is activated by the bottom plate, the LCT lift motor stops. A156/A160/A162 2-90...

  • Page 139: By-Pass Feed Table

    When there is no paper on the by-pass feed table, the paper end feeler [C] drops into the cutout in the lower guide plate and the by-pass feed paper end sensor [D] is deactivated. 2-91 A156/A160/A162...

  • Page 140: By-Pass Feed Paper Width Detection

    SP5-019. The reading from the sensor will be ignored if this SP mode is used to select an exotic paper size. However, if the user attempts to use a size of paper that is different from that agreed with the technician for this setting, a paper jam will occur. A156/A160/A162 2-92...

  • Page 141: Paper Registration

    The registration and relay rollers feed the paper to the image transfer section. The registration sensor is also used for paper misfeed detection. 2-93 A156/A160/A162...

  • Page 142: Paper Feed And Misfeed Detection Timing

    11.11 PAPER FEED AND MISFEED DETECTION TIMING 11.11.1 Paper Feed Tray A153/A155/A156 copiers (A4 sideways) L.E. (Leading Edge): Start Time for Scanning the Original A157/A159/A160 copiers (A4 sideways) J1 and J2: Checks whether the sensors (relay sensors and registration sensor) are activated within 500 ms after the designated time for these sensors.
  • Page 143 A155/A156 copiers (A4 sideways; two copies of a single-page original) A159/A160 copiers (A4 sideways; two copies of a single-page original) J1: Checks whether the registration sensor is activated when the registration clutch is turned on. 2-95 A156/A160/A162...

  • Page 144: By-Pass Feed

    Rev. 7/95 11.11.2 By-pass Feed A153/A155/A156 copiers (A4 sideways) A157/A159/A160 copiers (A4 sideways) J1: Checks whether the registration sensor is activated when the registration clutch is turned on. 11.11.3 (A160/A157) Copier (A4 sideways; two copies of a single-page original) J1: Checks whether the registration sensor is activated when the registration clutch is turned on.
  • Page 145 – A156 copier – The duplex tray is used for multiple two-sided and single two-sided copying. Note the paper feed path differences between the A156 and the A160. Timing of the duplex function is started when the paper actuates the fusing exit sensor [H].

  • Page 146: Drive Mechanism

    12.2 DRIVE MECHANISM – A160 copier – – A156 copier – The main motor [A] drives the transport rollers [B] through the timing belts [C]. All rollers in the duplex tray are driven by the duplex feed motor [D] through a series of gears and a timing belt [E]. Helical gears are used to reduce noise.

  • Page 147: Turn Guide Section

    The copy is then directed to the duplex entrance guide by the transport rollers [C]. There is a duplex entrance sensor [D] for paper misfeed detection. 2-99 A156/A160/A162...

  • Page 148: Duplex Entrance To Duplex Tray

    The mylar presses the copy against the duplex feed rollers, ensuring that the trailing edge of the copy clears the guide plate. The duplex turn sensor [E] detects the trailing edge of the paper as it enters the tray. A156/A160/A162 2-100...

  • Page 149: Duplex Stacking

    (This is done 690 ms [A156] or 920 ms [A160] after the duplex turn sensor detects the trailing edge of copy paper. The duplex turn sensor is [E] in the diagram on the previous page) Shortly after this, the jogger fences move back to their previous positions.

  • Page 150: Paper Feed From The Duplex Tray

    The pin [D] on the clutch lifts up the duplex lift lever [E] through a spring, raising the duplex bottom plate [F]. When the duplex feed motor rotates clockwise again, the cam clutch rotates counterclockwise, and the bottom plate lowers. A156/A160/A162 2-102...

  • Page 151: Paper Feed System

    [G]. The sensor sends the signal to the CPU to stop the next paper feed cycle. For a diagram of the paper feed path, see "Paper Path - Duplex Copying" in the Overall Machine Information section. 2-103 A156/A160/A162...

  • Page 152: Image Fusing

    7. Pressure springs 2. Thermistors (2 pcs) 8. Pressure roller 3. Secondary fusing lamp 9. Cleaning roller 4. Main fusing lamp 10. Fusing exit roller 5. Hot roller 11. Fusing exit sensor 6. Lower entrance guide 12. Hot roller strippers A156/A160/A162 2-104...

  • Page 153: Fusing Drive And Release Mechanism

    When the front cover is opened, the actuator plate [F] pulls release wire [G]. The wire pulls the fusing unit gear bracket [H] and the fusing unit drive is disengaged. 2-105 A156/A160/A162...

  • Page 154: Fusing Entrance Guide Shift Mechanism

    There are three screw holes on each side for securing the entrance guide. Normally, the center screw hole on each side is used. The other screw holes are spare in case the center holes get damaged. A156/A160/A162 2-106...

  • Page 155: Pressure Roller

    This is because the cleaning roller is made of metal and collects adhering matter more easily than the pressure roller (which has a teflon coating). 2-107 A156/A160/A162...

  • Page 156: Fusing Lamp Control

    The temperatures at the center and the side are monitored by individual thermistors [C]. Paper of various sizes will cause the hot roller to give up heat at different rates. The two thermistors detect this change and turn on the lamps accordingly. A156/A160/A162 2-108...
  • Page 157 °C °C °C °C Main Secondary Main Fusing Lamp Secondary Fusing Lamp Mains Frequency – A153/A155/A156 copiers – Fusing Lamp Standby Temp. Operation Temp. Main 165°C 180°C A153/A155/A156 copiers Secondary 160°C 175°C Main 160°C 175°C A157/A159/A160 copiers Secondary 160°C 175°C When the main switch turns on, the CPU checks the frequency of the A.C.
  • Page 158 Conversely, if the roller temperature is high, the duty cycles will be smaller to reduce the temperature. Phase control mode is selected only if the user has a problem with electrical noise on the same circuit or interference. A156/A160/A162 2-110...

  • Page 159: Overheat Protection

    (A157/A160) copier, faster warm-up may be achieved, but fusing problems may occur during multi-copy runs due to a lack of heat for the higher copy speed. The secondary fusing lamp is the same as for the base copier. 2-111 A156/A160/A162...

  • Page 161: Auto Reverse Document Feeder A548

    AUTO REVERSE DOCUMENT FEEDER A548...

  • Page 163: Specifications

    One flat belt Power Consumption: 45 W 24 V ± 10% from the copier, 1.8 A Power Source: Dimensions (W x D x H): 610 x 507 x 130 mm (24.0" x 20.0" x 5.1") Weight: Approximately 10.5 kg (23.2 lb) A156/A160/A162...

  • Page 164: Component Layout

    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...

  • Page 165: Electrical Components

    5. Feed-in Motor 14. Original Width Sensor - 1 6. Belt Drive Motor 15. Original Width Sensor - 2 7. DF Main Board 16. Original Width Sensor - 3 8. Inverter Solenoid 17. Registration Sensor 9. Feed-out Cover Open Sensor A156/A160/A162...

  • Page 166: Electrical Component Description

    Energizes to invert the original when SOL2 Inverter copying two-sided originals PCB1 DF Main Board Controls all DF functions Indicators (Lamps) Informs the operator that the DF is in the Ready down position. Informs the operator that the auto feed Auto mode is available. A156/A160/A162...

  • Page 167: Detailed Descriptions

    [D] to press the originals against the pick-up rollers [E]. An anti-static brush [F] is installed to eliminate static electricity caused during the original pick-up process. A156/A160/A162...

  • Page 168: Separation And Paper Feed Mechanism

    To prepare the next original, the feed-in motor turns clockwise to separate the second original and the motor turns off when the registration sensor detects the second original. When it is time for the second original to be fed to the exposure glass, the feed-in motor turns counter clockwise. A156/A160/A162...

  • Page 169: Friction Belt Drive Mechanism

    [C] or the original changes. This prevents multiple feeding or causing originals to become dirty. The reverse movement of the friction belt will not affect the next original because the pressure of the press lever holds the originals in place. A156/A160/A162...

  • Page 170: Original Size Detection

    The DF CPU counts the feed-in motor’s drive pulses during the on timing of the registration sensor. Based on this pulse count, the CPU determines the original length. The machine detects the original size by the total combination of all four sensors. A156/A160/A162...

  • Page 171: Paper Transport Mechanism

    The correction for this 3.5 mm gap is compensated for by the position of the lens unit. (Also see "Horizontal Lens Positioning" in the Optics section of the manual for the copier main body.) A156/A160/A162...

  • Page 172: Thick/Thin Original Modes

    To protect originals from being damaged by the movements of the transfer belt, thin original mode can be selected. The belt drive motor stops shortly after the original trailing edge passes the registration sensor. This stops the original at the correct position on the exposure glass. A156/A160/A162 3-10...

  • Page 173: Original Feed-Out Mechanism

    [A] turn on. The feed-out sensor [B] installed in the feed-out section counts the number of pulses to calculate how long the feed-out motor must stay on to feed the original out of the machine completely. 3-11 A156/A160/A162...

  • Page 174: Two-Sided Original Feed Mechanism

    When the scanner reaches the return position, the copier’s CPU sends the invert original signal to the DF CPU in order to make a copy of the front side. The original is inverted in the same way as for copying the back side, as explained earlier on this page. A156/A160/A162 3-12...

  • Page 175: Timing Charts

    5. TIMING CHARTS A4 SIDEWAYS: 1 SIDED ORIGINAL 3-13 A156/A160/A162...

  • Page 176: Combine 2 Original Mode

    COMBINE 2 ORIGINAL MODE A156/A160/A162 3-14...

  • Page 177: A4 Sideways: Duplex

    A4 SIDEWAYS: DUPLEX 3-15 A156/A160/A162...

  • Page 179: Paper Tray Unit

    PAPER TRAY UNIT A550/549...

  • Page 181: Specifications

    DC 24V, 5V and AC 120V, 220~240V from the main machine Power Consumption: Maximum 110.5 W Average 50 W Dimensions: 620 mm/24.4" (width) X 632 mm /24.9" (depth) X 390 mm/15.4" (height) Weight: Less than 36 kg/79.4 lb (Two-tray type) Less than 38 kg/83.8 lb (Three-tray type) A156/A160/A162...

  • Page 182: 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. Reverse Roller A156/A160/A162...

  • Page 183: Drive Layout

    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...
  • Page 184 Paper pick-up 3 (A549 SOL3 only) SOL4 Separation 1 Lifts/drops the separation roller SOL5 Separation 2 SOL6 Separation 3 (A549 Only) Heaters Tray (Option) Turns on when the main switch is off to keep the paper in the trays dry Tray (Option) A156/A160/A162...

  • Page 185: Overview

    The paper size for each paper tray is input at the operation panel, either by the user or by a technician. All the electrical components of the paper tray are controlled by the copier main board through the tray interface board. A156/A160/A162...

  • Page 186: Drive Mechanism

    The paper feed clutch is energized 300 ms after the main motor starts to rotate. When the paper feed clutch for the selected paper tray is energized, paper is fed from the paper tray to the main machine through the relay rollers. A156/A160/A162...
  • Page 187 5. PAPER FEED AND MISFEED DETECTION TIMING A4 Sideways, Lower Paper Feed Station, Line speed 200 mm/s J1 and J2: Checks whether the sensor is activated within 500 ms after the designated time for these sensors. A156/A160/A162...
  • Page 189 PAPER TRAY UNIT A553...
  • Page 190 Power Source: DC 24V, 5V and AC 120V, 220~240V from the main machine Power Consumption: Maximum 43 W Average 22 W Dimensions: 620 mm/24.4" (width) X 632 mm /24.9" (depth) X 390 mm/15.4" (height) Weight: Less than 30 kg/66 lb A156/A160/A162...
  • Page 191 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. Paper Feed Clutch 1 5. Relay Clutch 3. Paper Feed Clutch 2 A156/A160/A162...
  • Page 192 Starts to feed paper from the tray Paper feed 2 Relay Drives the rollers in the paper trays Heaters Tray (Option) Turns on when the main switch is off, to keep the paper in the trays dry Tray (Option) A156/A160/A162...
  • Page 193 The paper size for each paper tray is input at the operation panel, either by the technician or by the user. All the electrical components of the paper tray are controlled by the copier main board through the tray interface board. A156/A160/A162...
  • Page 194 The paper feed clutch [C] is energized 300 ms after the main motor starts to rotate. When the paper feed clutch for the selected paper tray is energized, paper is fed from the paper tray to the main frame through the relay rollers. A156/A160/A162...

  • Page 195: Paper Feed And Misfeed Detection Timing

    Rev. 7/95 5. PAPER FEED AND MISFEED DETECTION TIMING A4 Sideways. Lower Paper Feed Station 200 mm/s J1 and J2: Checks whether the sensor is activeted within 667 ms after the designated time for these sensor. A156/A160/A162...
  • Page 196 SORTER STAPLER A554...

  • Page 198: Specifications

    " x 14" or larger: 2 – 10 copies Stapling Position: (Diagonal) (Horizontal) a = 16 ± 3 mm a = b = 0.63" ± 0.12" = 6 ± 3 mm b = 10 ± 3 mm = 0.24" ± 0.12" = 0.39" ± 0.12" A156/A160/A162...
  • Page 199 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 200: Component Layout

    2. Proof Tray Exit Rollers 9. Grip Assembly 3. Vertical Transport Rollers 10. Bin Support Block 4. Turn Gate 11. Bins 5. Bin Transport Belt 12. Support Bin 6. Bin Transport Roller 13. Jogger Bar 7. Bin Exit Roller A156/A160/A162...

  • Page 201: Drive Layout

    22. Front Bin Block Support Block 17. Vertical Transport 10. Jogger Motor Pulley Drive Pulley 13. Lower Jogger Drive Belt 15. Bin Transport Drive Gear 5. Jogger Drive Shaft 14. Bin Transport Belts 1. Upper Jogger Drive Belt 23. Jogger Bar A156/A160/A162...

  • Page 202: Electrical Component Description

    Bin H.P. (home) position. Bin Exit Detects paper jams at the bin exit area. Proof Tray Exit Detects paper jams at the proof tray exit area. Monitors the roller drive motor speed by Roller Drive Timing detecting the timing disk. A156/A160/A162...
  • Page 203 Cuts the 24 Vdc line when the sorter stapler unit Sorter Stapler Set is open. Staple End Detects the staple end condition. Staple Guide Detects whether the staple guide plate is closed. Detects whether the staple hammer is at the Staple H.P. home position. A156/A160/A162...

  • Page 204: Basic Operation

    [C] rotates all the rollers in the S/S paper path. At the same time, the turn gate solenoid [D] is energized and the turn gate turns clockwise. The turn gate directs copies to the proof tray [E] through the vertical transport and proof tray exit rollers [F and G]. A156/A160/A162...
  • Page 205 This bin movement is done for each copy in sort mode and for the final copy of each original in stack mode. The up and down movement of the bins in both sort and stack modes is the same as for other moving bin type sorters. A156/A160/A162...

  • Page 206: Staple Mode

    The grippers bring the copies up underneath the stapler. At the same time, the jogger bar jogs the copies stacked in the second bin to prepare for the next stapling operation. Then the jogger bar returns to the position 15 mm away from the side edge of the paper. A156/A160/A162...
  • Page 207 Start key, the copies will be delivered to each bin and stapled automatically. 2) Manual stapling: In sort mode, after copies are sorted in the bins, the copies will be stapled when the user presses the staple key after copying. In stack mode, manual stapling is impossible. A156/A160/A162 6-10...

  • Page 208: Turn Gate Section

    [D] to the bin transport section. The solenoid lever [E] is bent at a right angle to ensure that the lever moves only if the solenoid switches from on to off, or from off to on. 6-11 A156/A160/A162...

  • Page 209: Roller Drive And Control

    PCB. Then the copier signals the S/S to stop the roller drive motor. The S/S CPU monitors the roller drive motor speed by counting pulses from the timing disc [K] through the roller drive timing sensor [L]. A156/A160/A162 6-12...
  • Page 210 The high speed is almost double the normal speed, and it changes depending on the paper size (900, 960, or 1,000 mm/second). 6-13 A156/A160/A162...

  • Page 211: Bin Drive And Control

    M]. Bin lift timing sensor 1 (blue connector) is used for counting the timing pulses. Bin lift timing sensor 2 (white connector) is used to determine the motor stop timing so that the edge of the timing disc slots is not positioned at timing sensor 1. A156/A160/A162 6-14...
  • Page 212 If the bin lift motor fails to stop lowering the bins at the bin home position, the rear bin lift wire [F] slackens. Then the wire tension switch [G] (which is a normally-open type) is deactivated, which opens the 24 Vdc line to the bin lift motor. 6-15 A156/A160/A162...
  • Page 213 4. The lowered end fence mylar helps to prevent the copy in the first bin from moving out of the jogged position. The end fence mylar and block of the second bin are ready to receive the next copy. A156/A160/A162 6-16...

  • Page 214: Jogger Section

    This jogger bar movement is performed for each copy to square the copy stack. In the automatic or manual staple modes, the jogger bar also moves to ensure that the stacked copies are squared before stapling. For how the jogger moves, see "Basic Operation - Staple Mode". 6-17 A156/A160/A162...
  • Page 215 If the selected paper size does not match the stapling specifications. • If copies of different width are delivered to the bins. 2. If there is paper in a bin before the main switch is turned on, the sort/stack mode is disabled when the sorter key is pressed. A156/A160/A162 6-18...

  • Page 216: Grip Assembly

    Figure 3: When the high lobe of the grip cam [L] (the small cam on the dual cam plate) pushes up the grip cam follower, the grippers close to grip the copies that are stacked in the bin. 6-19 A156/A160/A162...
  • Page 217 When the stapler motor stops, the grip motor starts rotating in reverse. Then the gripper assembly brings back the stapled copies into the bin, the grippers open, and the gripper assembly returns to the home position. A156/A160/A162 6-20...

  • Page 218: Stapler

    [I]. The hammer and the clincher staple the copies. Then, while the staple arms rotate clockwise, the hammer rises and the clincher lowers. When the staple home position switch (a normally-closed type) [J] is deactivated, the stapler motor stops. 6-21 A156/A160/A162...
  • Page 219 Add Staples indicator lights on the copier operation panel. The stapler can be swung on the stapler support bracket [E] and it has two lock positions. One is for horizontal stapling and the other is for diagonal stapling (at 25 degrees). A156/A160/A162 6-22...
  • Page 220 If the paper size in the bin does not match the stapling specifications. • If only one copy is delivered to the bin. • If copies of different width are delivered to the bin. • If some already-stapled copies are present in the bin. 6-23 A156/A160/A162...

  • Page 221: Jam Detection And Stapler Error

    Therefore, to match the sorter stapler speed to the copier’s, the copier sends a signal to the S/S CPU; this controls the normal speed of the roller drive motor (the speed in high speed mode never changes) and this generates the pulse rate. A156/A160/A162 6-24...

  • Page 222: Stapler Error

    • The first time an abnormal condition of the stapler motor or grip motor is detected. The second time an abnormal condition is detected, the copier’s operation panel will indicate a service call code. 6-25 A156/A160/A162...

  • Page 223: Timing Charts

    370 ms B5 lengthwise 230 ms 0 ms 11" x 17" 295 ms 130 ms " x 14" 675 ms 90 ms " x 11" sideways 130 ms 265 ms " x 11" lengthwise 625 ms 0 ms A156/A160/A162 6-26...
  • Page 224 Timing Chart 3: Stapling (A4 sideways, 2 copies for 5 bins) Staple ON Staple count Job completion signal signal signal Interface Bin Lift Motor Jogger Motor Returns to H.P. Grip Motor Stapler Motor 1 staple cycle 6-27 A156/A160/A162...

  • Page 226: Sorter Stapler A555

    SORTER STAPLER A555...

  • Page 228: Specifications

    50 copies (81 ~ 128 g/m / 22 ~ 34 lb) 30 copies (129 ~ 157 g/m / 35 ~ 42 lb) Number of Bins: 10 bins + proof tray a = 6 ± 3 mm Stapling Position: b = 6 ± 3 mm A156/A160/A162...
  • Page 229 Average: less than 33 W Average for Sorting: less than 25 W Average for Stapling: less than 33 W Weight: 12.4 kg (27.4 lb) Dimensions (W x D x H): 381 x 548 x 443 mm (15.0" x 21.6" x 17.5") A156/A160/A162...

  • Page 230: Component Layout

    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 A156/A160/A162...

  • Page 231: Drive Layout

    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...

  • Page 232: Electrical Component Description

    Detects when the staples run out Switches Door Safety Cuts the dc +24V supply when either the unit or the stapler cover is opened. Stapler Cuts the signals to the stapler. Circuit Board PCB1 Main Controls all sorter/stapler functions A156/A160/A162...

  • Page 233: Basic Operation

    The jogger plate [E] squares the copies after each copy has been fed to a bin. After the copies of the first original have been delivered to each bin, the sorter stapler maintains its status (the bin drive motor does not rotate). A156/A160/A162...
  • Page 234 After one set of copies for the first original has been delivered to the top bin, the bin drive motor moves the bins up one step. Then, one set of copies of the second original will be delivered to the next bin. A156/A160/A162...

  • Page 235: Staple Mode

    Then the grip assembly goes back to the normal position. The bin either advances or descends one step depending on whether the number of originals is odd or even [D]. When the final set of copies has been stapled, the bins go back to the standby position. A156/A160/A162...
  • Page 236 Manual Stapling In platen cover mode, after the copies have been sorted into the bins, the staple mode LED starts to blink. If the sort key is pressed while this LED is blinking, the copies will be stapled. A156/A160/A162...

  • Page 237: Bin Drive Mechanism

    This leaves enough space to staple and stack the copies. Also, this reduces the total machine height. A156/A160/A162 7-10...

  • Page 238: Bin Home Position

    When the main switch is turned on, the sorter stapler initializes itself to check whether the component parts work or not. At this time, the bin drive motor raises the bins for a few moments, then it lowers the bins until the bottom bin actuates the bin home position sensor. 7-11 A156/A160/A162...

  • Page 239: Jogger Mechanism

    Then, the jogger motor drives the jogger plate to the width of the copy. Finally, the jogger plate moves inward to push all the copies against the front side frame, which squares the sheets of paper. Then the jogger plate returns to the home position. A156/A160/A162 7-12...

  • Page 240: Grip Assembly

    The actuator [J] on the cam gear activates the grip home position sensor once every rotation of the cam gear. This allows the sorter stapler to determine that the cam gear has rotated once. 7-13 A156/A160/A162...

  • Page 241: Stapler Unit

    [H], the sorter stapler enters the staple near end condition. After the current job is completed, the Add Staples indicator lights on the operation panel. Then the copier cannot be used whenever the staple mode is selected. A156/A160/A162 7-14...

  • Page 242: Stapler Switch

    2. Under the following conditions, staple mode is canceled if it had been selected. If paper is inserted into a bin by hand while the staple mode is selected. If only one sheet is delivered to the bin. If the number of sheets to be stapled exceeds the stapler capacity. 7-15 A156/A160/A162...

  • Page 243: Paper Feed And Misfeed Detection Timing

    A3/11"x17" 138 ms 292 ms lengthwise/ 312 ms 118 ms "x11" 218 ms 212 ms B5 sideways 218 ms 212 ms A4 sideways/ 138 ms 292 ms B5 lengthwise 368 ms 62 ms 11"x8 " A156/A160/A162 7-16...
  • Page 244 – Staple Mode – A4 sideways, two copies of a two-page original, after sorting, 150 mm/s 7-17 A156/A160/A162...

  • Page 245: Jam Detection

    1. If the stapler paper sensor is on when the main switch turns on or just as the stapler cover is closed. 2. If the stapler paper sensor stays on after the stapling job has been finished. A156/A160/A162 7-18...

  • Page 246: Sorter A556

    SORTER A556...

  • Page 248: Specifications

    A3, 11" x 17" Power Source: +5 volts and +24 volts from the copier Power Consumption: 24 W Dimensions: 346 mm x 474 mm x 338 mm (W x D x H) 13.6" x 18.7" x 13.3" Weight: 12.5 kg (27.8 lb) A156/A160/A162...

  • Page 249: Mechanical Component Layout

    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...

  • Page 250: Electrical Component Layout

    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) A156/A160/A162...

  • Page 251: Electrical Component Descriptions

    (1 bin is changed for each half-turn) Switch Cover Safety Switch Detects when the sorter cover is opened Printed Circuit Board Sorter Main Board Controls all sorter functions. Communicates with the copier main PCB1 board through the interface PCB A156/A160/A162...

  • Page 252: Basic Operation

    999 copy limit of the copier. However, the physical capacity of the bins is a good deal less. (See "Bin Capacity" in the specifications.) When all 20 bins have been used, the wheel drive motor turns on until all the bins have been lowered (including the proof tray). A156/A160/A162...

  • Page 253: Example Of Sort Mode Operation

    3) The third copy feeds to the third bin. As this is the final copy, the wheel drive motor does not turn on this time after the paper sensor turns off. (The sorter will stay at this position until auto-reset or until copying resumes.) A156/A160/A162...
  • Page 254 6) The third copy is fed to the first bin. The wheel drive motor does not turn on after the paper sensor turns off. - Start Key Pressed for the Third Copy Run - 7) The first sequence (1, 2, and 3) is repeated. A156/A160/A162...

  • Page 255: Bin Drive Mechanism

    Plastic spacers [G] on both ends of each bin keep the bins separated. To move the bins up, the wheel drive motor turns clockwise (as viewed from the front). A timing belt [H] turns the transfer wheels [I]. A156/A160/A162...
  • Page 256 Also, the shape of the transfer wheels has been modified from previous models to reduce banding on copies that is caused by vertical slippage due to the movement of the sorter bins. A156/A160/A162...

  • Page 257: Bins

    The stoppers [B] prevent copies from sliding back into the sorter after they have been fed out. The arrangement of these stoppers is different for even and odd numbered bins. Three leaf springs [C] on the underside of each bin hold the copies flat in the underlying bin. A156/A160/A162 8-10...

  • Page 258: Exit Rollers

    [A]. When the copier sends a signal to the selected paper feed station to feed paper, the CPU sends a signal to the sorter to turn on the roller drive motor. After copying, the roller drive motor turns off at the same time as the copier main motor. 8-11 A156/A160/A162...

  • Page 259: Timing Chart

    T3: 0.25 second after the paper sensor turns off, the wheel drive motor starts rotating and shifts the bin. T4: When the wheel sensor is de-actuated, the wheel drive motor turns off. T5: 0.42 second after the paper sensor turns off, the roller drive motor stops. A156/A160/A162 8-12...

  • Page 260: Sorter A557

    SORTER (A557)

  • Page 262: Specifications

    A3, 11" x 17" Power Source: +5 volts and +24 volts from the copier Power Consumption: 15 W Dimensions: 402 mm x 455 mm x 217 mm (W x D x H) (15.7" x 17.8" x 16.7") Weight: 7.5 kg (16.5 lb) A156/A160/A162...

  • Page 263: Component Layout

    4. Upper Paper Guide 5. Lower Paper Guide 6. Bin Guide — Electrical Components — 1. Sorter Main Board 5. Bin Drive Motor 2. Wheel Switch 6. Sorter Switch 3. Roller Drive Motor 7. Bin Home Position Switch 4. Paper Sensor A156/A160/A162...

  • Page 264: Electrical Component Descriptions

    Serves as the misfeed sensor for the sorter Paper Sensor and also sets exit roller and bin drive timing. Printed Circuit Boards Serves as the communication board PCB1 Sorter Main Board between the copier main board and the sorter. A156/A160/A162...

  • Page 265: Basic Operation

    At 250 milliseconds after the last copy of the original has gone through the paper sensor, the bin drive motor turns on to advance the bin one step. A156/A160/A162...
  • Page 266 [D]. The shaft of the lower exit roller is a cylindrical cavity type which rotates around the transfer wheel shaft [E]. The paper sensor is positioned just in front of the exit rollers. The paper sensor detects misfeeds in the sorter. A156/A160/A162...
  • Page 267 10th bin (the 10th bin is permanently fixed in position). The upper and lower paper guides pivot up and down depending on the height of the bin to be picked up or released. A156/A160/A162...
  • Page 268 [J]. The actuator cam has two flat sides that are 180 degrees apart and is mounted behind the rear transfer wheel. A pulse is generated each time one of the lobes of the actuator cam passes the wheel switch. A156/A160/A162...
  • Page 269 In misfeed condition, the "Check Paper Path" and "Misfeed Location" indicators light and copier operation is disabled. To recover the sorter from the misfeed condition, the sorter has to be slid away from the copier, the misfed paper removed, and the sorter returned to its original position. A156/A160/A162...

This manual is also suitable for:

A153A161A207A208A211A160 ... Show all

Table of Contents