Ricoh FT5535 Service Manual
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Ricoh FT5535 Service Manual

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FT5535/5035/4527/4027/4522/4022
FIELD SERVICE MANUAL

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Summary of Contents for Ricoh FT5535

  • Page 1 FT5535/5035/4527/4027/4522/4022 FIELD SERVICE MANUAL...
  • Page 2 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...
  • Page 3 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. FT5535/4527/4522...
  • Page 4 SECTION 1 OVERALL MACHINE INFORMATION...
  • Page 5 , 17 ~ 24 lb Reproduction Ratios: 4 Enlargement and 6 Reduction A4/A3 Version LT/DLT Version 200% 200% 141% 155% Enlargement 122% 129% 115% 121% Full size 100% 100% Reduction Power Source: 120V/60Hz: More than 12 A (for North America) FT5535/4527/4522...
  • Page 6 27 dB(A) (L Stand-by 33 dB(A) 27 dB(A) 32 dB(A) 27 dB(A) (L NOTE: The above measurements are to be made according to ISO 7779. * : Full System: Copier + ADF + Paper Tray Unit +10 Bin S/S. FT5535/4527/4522...
  • Page 7 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 8 Original length sensor for 11" x 15" size paper (only for LT/DLT version) • ADS sensor for particular types of red original • Zoom (10 Key) Function Decal * • Margin Adjustment Function Decal* *Not used on FT4022/4522 (A161/A162) FT5535/4527/4522...
  • Page 9 SECTION 2 COMPONENT LAYOUT AND DESCRIPTION...
  • Page 10 Rev. 7/95 1. MACHINE CONFIGURATION COPIER FT5535/4527/4522...
  • Page 11 Rev. 7/95 OPTIONAL EQUIPMENT * Only available on models FT5535 and FT4527 ** Not for use on FT4022/4522(A161/A163) copiers. FT5535/4527/4522...
  • Page 12 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. FT5535/4527/4522...
  • Page 13 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. FT5535/4527/4522...
  • Page 14 14. Toner Supply Unit 34. Pressure Roller 15. Pre-transfer Lamp 35. Hot Roller 16. Development Unit 36. Junction Gate 17. Registration Rollers 37. Hot Roller Strippers 18. Feed Roller 38. Transport Fan 19. Pick-up Roller 20. Separation Roller 21. Large Capacity Tray FT5535/4527/4522...

  • Page 15: Paper Path

    Rev. 7/95 3. PAPER PATH NORMAL COPYING – A156 copier – –A160/A162 copier – FT5535/4527/4522...
  • Page 16 Rev. 7/95 DUPLEX COPYING – A156 copier – – A160/A162 copier – FT5535/4527/4522...

  • Page 17: Table Of Contents

    Lens Horizontal Drive Shifts the lens horizontal position. Duplex Feed Drives the feed roller and moves the bottom (Duplex machines only) plate up and down. End Fence Jogger Drives the end fence jogger to square the (Duplex machines only) paper stack. FT5535/4527/4522...
  • Page 18 Platen Cover Informs the CPU whether the platen cover is up or down (related to APS/ARE functions). ARE: Auto Reduce and Enlarge Toner End Instructs the CPU to add toner to the toner supply unit, and detects toner end conditions. FT5535/4527/4522...
  • Page 19 Supplies power to the copier. Front Cover Safety Detects whether the front door is open and via SW11 relays cuts the ac power. Exit Cover Safety Detects whether the exit cover is open or not. SW12 (A157/A160 machines only) FT5535/4527/4522 2-10...
  • Page 20 Reduces the charge remaining on the drum surface before transfer. Quenching Neutralizes any charge remaining on the drum surface after cleaning. Erase After exposure, this eliminates the charge on areas of the drum that will not be used for the image. 2-11 FT5535/4527/4522...
  • Page 21 Others Circuit Breaker Provides back-up high current protection for (220 ~ 240V machines electrical components. only) Choke Coil Removes high frequency current. Transformer Steps down the wall voltage to 100 Vac. (220 ~ 240V machines only) FT5535/4527/4522 2-12...

  • Page 22: 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 2-13 FT5535/4527/4522...
  • Page 23 1. Upper Paper Feed Clutch Gear (A153/A155 only) 2. Lower Paper Feed Clutch Gear 3. Relay Clutch Gear A157/A160/A161/A162 1. Upper Paper Feed Clutch Gear (A157and A161 only) 2. Lower Paper Feed Clutch Gear 3. Relay Clutch Gear FT5535/4527/4522 2-14...
  • Page 24 SECTION 3 INSTALLATION...

  • Page 25: Installation Requirements

    9. Place the copier on a strong and level base. 10. Do not place the machine where it may be subjected to strong vibrations. 1.2 MACHINE LEVEL 1. Front to back: Within 5 mm (0.2") of level 2. Right to left: Within 5 mm (0.2") of level FT5535/4527/4522...
  • Page 26 *2. Copier only + Receiving Tray 103.0 cm/40.6" (with LCT: 125.8 cm/49.6") Copier + A554 Sorter/Stapler 103.2 cm/40.7" (with LCT: 126.0 cm/49.7") Copier + A555 Sorter/Stapler 100.1 cm/39.5" (with LCT: 122.9 cm/48.4") Copier + A556 Sorter 96.6 cm/38.1" (with LCT: 119.4 cm/47.1") FT5535/4527/4522...
  • Page 27 More than 7 A (for Europe) 220V/50Hz: More than 7 A (for Asia) 110V/60Hz: More than 12 A (for Taiwan) 220V/60Hz: More than 7 A (for Saudi Arabia, Philippines) 2. Permissible voltage fluctuation: 10% 3. Do not set anything on the power cord. FT5535/4527/4522...

  • Page 28: Copier Installation

    5. Combine Originals Explanation Decal (except for the A156 copier) ..1 6. Receiving Tray..................1 7. Operating Instructions (except for –27 machines)........1 8. User Survey Card (–17 machines only)........... 1 9. New Equipment Condition Report ............1 FT5535/4527/4522...
  • Page 29 [C]. Also, remove the strip of tape on the LCT. 3. Pull out the paper tray [D], and remove the strips of tape and the bottom plate stopper [E]. Then install the paper tray in the copier (1 tray for duplex machines and 2 trays for non-duplex machines). FT5535/4527/4522...
  • Page 30 3) Open the upper duplex guide plate [E] and remove the strips of tape [F]. 4) Open the lower duplex guide plate [G], and remove the styrofoam support [H] and the sheet of paper [I]. 5) Install the duplex tray in the copier. FT5535/4527/4522...
  • Page 31 8. Turn the "A1" lever [D] counterclockwise to lower the transfer belt unit. Then remove the cushion sheet [E]. 9. Remove the blade release wedge [F] together with the pick off pawl release mylar [G]. 10. Return the "A1" lever to the set position. FT5535/4527/4522...
  • Page 32 13. Remove the knob screw [E] and disconnect the white connector [F]. 14. Pull down the development unit lock lever [G] from under the plate and pull out the development unit [H]. Then place it on a clean sheet of paper. FT5535/4527/4522...
  • Page 33 17. Remount the toner supply unit on the development unit (2 screws) and connect the white connector. NOTE: Make sure that the positioning rib [E] sits in the groove [F]. 18. Install the development unit in the copier (1 knob screw and 1 connector). FT5535/4527/4522...
  • Page 34 21. Install a toner bottle by following the instructions placed on the reverse side of the front cover. 22. Swing in the toner bottle holder to its original position and close the front cover. 23. Plug in the copier and turn on the main switch. FT5535/4527/4522 3-10...
  • Page 35 4) Enter the number for the desired language in the three-digit indicator and press the "Enter" key. 1:English 2:French 3:German 4:Italian 5:Spanish 6:Swedish 7:Portuguese 8:Danish 9:Norwegian 10:Finnish 11:Dutch 27. Press the "Clear Modes" key three times to exit SP mode. 3-11 FT5535/4527/4522...
  • Page 36 34. All models except the A156: Attach the symbol explanation decal [E] to the top cover as shown. (If the ARDF will be installed, stick the decal on the ARDF exit cover. Refer to the ARDF installation procedure.) 35. Check the copy quality and machine operation. FT5535/4527/4522 3-12...

  • Page 37: Paper Size Selection

    A156 and A160 copiers The diagrams on this page By-pass Feed show how the paper feed stations are numbered in the various models. Copier 1st tray 2nd tray 3rd tray Paper Tray Unit 4th tray* NOTE: *A549 paper tray unit only 3-13 FT5535/4527/4522...
  • Page 38 " x 13") (lengthwise) F4 (8 " x 13") (lengthwise) 8" x 10" NOTE: For the 1st tray, a wider range of paper sizes can be selected with SP mode. See section 2.3.4 and "Service Tables - SP5-019: Paper Size Setting". FT5535/4527/4522 3-14...
  • Page 39 SP settings for each 3rd level program number are blinking in the reduce/enlarge indicator. *SPECIAL: See section 2.3.4 and "Service Tables - SP5-019: Paper Size Setting" for how to select from a wider range of paper sizes for the 1st tray. 3-15 FT5535/4527/4522...
  • Page 40 2.3.1 "Paper Feed Station Definition". If a special paper size is selected, the machine ignores the paper size set with the paper size slider. See Service Tables - Paper Size Settings for how to select a special paper size using SP5-019. FT5535/4527/4522 3-16...
  • Page 41 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. Clip......................3 4. Philips Pan Head Screw M4 x 6 .............. 4 3-17 FT5535/4527/4522...
  • Page 42 4. Attach the sorter adapter front cover [D] to the copier front cover (3 clips [E]) as shown. NOTE: Be sure to push the clips in completely. 5. Check that the rotation of the exit rollers [F] is synchronized with the rotation of the fusing unit knob [G]. FT5535/4527/4522 3-18...
  • Page 43 1. Remove the 20-bin sorter stapler and the sorter stapler mounting frame from the copier. (See "20-BIN SORTER STAPLER INSTALLATION PROCEDURE".) 2. A153, A155, A157, and A159 copiers: Remove the 1st and 2nd paper trays. 3. A156 and A160 copiers: Remove the duplex unit and the 1st paper tray. 3-19 FT5535/4527/4522...
  • Page 44 11. Clamp the harness [L] to the two clamps [J] and [M] as shown to prevent the harness from touching the carrying handle. NOTE: Tell the customer that even when the copier main switch is turned off, the copier power cord should be plugged in. Otherwise, the tray heater will not function. FT5535/4527/4522 3-20...
  • Page 45 2. Remove the rear cover. (See "Replacement and Adjustment - Outer Cover Removal".) 3. Insert the two clamps [A] as shown. 4. Mount the anti-condensation heater [B] (2 screws). 5. Pass the connector [C] through the opening [D]. 6. Clamp the harness [E] to the two clamps [A]. 3-21 FT5535/4527/4522...
  • Page 46 ADS sensor board. NOTE: Tell the customer that even when the copier main switch is turned off, the copier power cord should be plugged in. Otherwise, the optics anti-condensation heater will not function. FT5535/4527/4522 3-22...
  • Page 47 5. Mount the optional sensor [C] as shown (1 tapping screw). 6. Remount the lens housing cover [D] (2 tapping screws), and remove the light shielding mylar [E]. 7. Enter SP mode, and input "1" as the SP4-302 setting. (See "Service Tables - Service Program Mode".) 3-23 FT5535/4527/4522...
  • Page 48 7. Perform the ADS sensor initial setting with SP4-201. (See "Service Tables - Service Program Mode".) NOTE: A153, A155, and A156 copiers only: When remounting the optics cooling fan duct [A], be sure not to catch the sensor harness. FT5535/4527/4522 3-24...
  • Page 49 4. Mount the key counter holder [D] (2 screws). 5. Reinstall all the covers and check the key counter’s operation. 6. Make sure that SP mode 5-401 is set to 0, then switch the power off and cut JP2 on the main board. 3-25 FT5535/4527/4522...
  • Page 50 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. FT5535/4527/4522 3-26...
  • Page 51 SECTION 4 SERVICE TABLES...

  • Page 52: Service Remarks

    8. Apply setting powder to the entire surface of the drum before installing a new drum. 9. Process control data initial setting (see section 3.1, "Practical SP Mode Use Tables - Replacement and Cleaning") must be performed when a new drum is installed. FT5535/4527/4522...

  • Page 53: Drum Unit

    While the main switch is turned off, the drum heater must be turned on to keep the temperature around the drum charge roller over 15°C. This prevents the drum charge efficiency from being low for the first copy after the power is switched on. FT5535/4527/4522...

  • Page 54: Erase Lamp

    1. A narrower lead edge erase margin increases the possibility of fusing jams. The margin should be at least 1.0 mm. 2. After cleaning the erase lamp unit, rub it lightly with your finger to discharge any static electricity on the surface. FT5535/4527/4522...

  • Page 55: Development Unit

    Never use the toner in the used toner collection tank for toner recycling. 5. Do not bend the bias terminal at the rear side of the transfer belt unit. A bent terminal may cause a bad contact for the transfer charge circuit. FT5535/4527/4522...
  • Page 56 B size paper position when paper jams or non-feeds occur. (See Replacement and Adjustment - Section 6.5 Paper Feed Roller Replacement for A157/A159/A160.) This remark also applies to the A553 paper tray unit. FT5535/4527/4522...
  • Page 57 If the battery is short-circuited, RAM data will be destroyed in the worst case. 2. When carrying the copier, never lift it up by holding the LCT. Otherwise, the LCT will be broken. Hold the copier by the carrier handles in the bottom corners. FT5535/4527/4522...
  • Page 58 Auto Image Density indicator starts blinking, and the reduce/enlarge indicator turns off. How to leave the SP mode Press the key three times, or turn off the main switch. NOTE: The above procedure must be finished within 20 seconds. FT5535/4527/4522...
  • Page 59 3. The current setting will be displayed in the reduce/enlarge indicator. 4. Enter the required setting using the numeric keys, then press the key. (SP mode numbers and their possible settings are given in the SP mode table.) 5. Leave SP mode. FT5535/4527/4522...
  • Page 60 Total sheets of paper fed from the 3rd Tray of the SP7-204-005 Paper Tray Unit SP7-816-006 Total sheets of paper fed from the LCT SP7-204-006 SP7-816-007 Total sheets of paper fed from the By-pass Feed SP7-204-007 Table SP7-816-008 Total Duplex Paper Feeds SP7-204-008 FT5535/4527/4522...
  • Page 61 NOTE: Before pressing the key, be sure to check again whether you wish to reset these counters or not. 2. Press the key. The above counters are all reset. FT5535/4527/4522 4-10...
  • Page 62 (3) SP4-001: Exposure Lamp Voltage Adjustment (4) SP4-201: Auto ADS Gain Adjustment (5) SP3-105: Forced V Detection 5. Check the copy quality and the paper path and do any necessary adjustments (see Replacement and Adjustment - Copy Quality Adjustments). 4-11 FT5535/4527/4522...
  • Page 63 After doing SP5-801, execute the following procedure to return the machine to its normal operating condition. 1. Install a new OPC drum. 2. Install new developer. 3. Clean the optics, sensors, and inside the copier if necessary. FT5535/4527/4522 4-12...
  • Page 64 (5) SP4-001: Exposure Lamp Voltage Adjustment (6) SP4-201: Auto ADS Gain Adjustment (7) SP3-105: Forced V Detection 6. Check the copy quality and the paper path and do any necessary adjustments (see Replacement and Adjustment - Copy Quality Adjustments). 4-13 FT5535/4527/4522...
  • Page 65 Jogger Span Adjustment (End Fence) † 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 † FT5535/4527/4522 4-14...
  • Page 66 Exposure Lamp Voltage Adjustment † °4-002 Exposure Lamp Voltage Display † 4-008 Vertical Magnification Adjustment † 4-011-xxx Lens Horizontal H.P. Adjustments † 4-013 Scanner Free Run 4-101 Horizontal Magnification Adjustment † 4-102 Lens Error Correction † 4-103 Focus Adjustment † 4-15 FT5535/4527/4522...
  • Page 67 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. Do not change the factory setting. 5-801 Memory All Clear † FT5535/4527/4522 4-16...
  • Page 68 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. °7-101-xxx Total Copies by Paper Size † °7-203 Drum Counter † °7-204-xxx Feed Unit Counter † °7-205 DF Counter † 4-17 FT5535/4527/4522...
  • Page 69 PM Counter Clear °7-807-001 SC Counter Clear † °7-807-002 Copy Jam Counter Reset † °7-807-003 Original Jam Counter Reset † °7-808 Counter All Clear °7-810 Copy Counter Clear °7-811 DF Counter Clear °7-816-xxx Feed Unit Counter Clear † FT5535/4527/4522 4-18...
  • Page 70 Default = 180 Adjustment roller. (Type 1) (Main Fusing The selected temperature is displayed in the Default = 175 reduce/enlarge indicator. (Type 2) Lamp) † (1°C per step [range: 170°C to 190°C]) 4-19 FT5535/4527/4522...
  • Page 71 Adjusts the stop position of the jogger end 0 ~ 32 Adjustment fence span of the duplex unit. Default = 16 (End Fence) † (0.5 mm per step [range: –8.0 mm to +8.0 mm]) A156 and A160 copiers only FT5535/4527/4522 4-20...
  • Page 72 Default = 6 (0V) Adjustment (for The adjustment factor set with this SP mode is making V added to the base voltage. patterns) † (20 V per step [Range: Base voltage - 10 V to Base voltage + 80 V] 4-21 FT5535/4527/4522...
  • Page 73 Selects the toner supply ratio for Fixed Supply 1: 2% Ratio Mode. 2: 4% (Fixed Supply For example, if the user normally makes 3: 6% Mode) † copies of originals that are about 6% black, 4: 11% select the 6% setting for best results. FT5535/4527/4522 4-22...
  • Page 74 12 (–20 µA): Type 2 2-801 Developer After the Start key is pressed, the developer is Agitation agitated. To stop, press the "Clear Stop" key. Use this SP mode if the machine has not been used for a long time. 4-23 FT5535/4527/4522...
  • Page 75 Displays the current V value [%]. This is the value currently being used for V Display † correction. 3-111 Current Displays the current V value [%] This is the value currently being used for V Display † correction. FT5535/4527/4522 4-24...
  • Page 76 For 115 V machines, the actual applied voltage = displayed value x 1.1412. After doing this SP mode, ADS initial setting (SP4-201) and forced V detection (SP3-105) must also be done. See "Replacement and Adjustment - Copy Quality Adjustments" for how to adjust. 4-25 FT5535/4527/4522...
  • Page 77 Adjusts the magnification perpendicular to the 0 ~ 32 Magnification direction of paper travel. Default =16 ‡ Adjustment † (0.2% per step [Range: –1.6% to +1.6%]) See "Replacement and Adjustment - Copy Quality Adjustments" for how to adjust. FT5535/4527/4522 4-26...
  • Page 78 If "YES" is selected, paper sizes that cannot be detected by the APS sensors are regarded as A5 lengthwise (for A4 models) or 5 " x " (for LT models). If "NO" is selected, "Check Paper Size" will be displayed. 4-27 FT5535/4527/4522...
  • Page 79 1 ~ 999 Quantity † entered. Default = 999 (Copy Limit) • °5-019-001 Paper Size Set Sets the paper size for each paper tray and For how to input † feed station. the settings, see 5-019-008 section 2.7. FT5535/4527/4522 4-28...
  • Page 80 Adjustment † 2: 10 mm SP5-908 must be at 1 for this to have any LT version effect. A strip of the selected width will be 1: 0.20" erased around the edges of the copy image. 2: 0.40" 4-29 FT5535/4527/4522...
  • Page 81 The current user code is displayed in copy counter, and the copy count for that user code is displayed in the reduce/enlarge indicator. • Hold down the " " key to display the last three digits. Use the keys to check each user code counter. FT5535/4527/4522 4-30...
  • Page 82 RDS/CSS Alarm Level for SC (Service Call Alarm Level Setting) † Used in Japan only. Do not change the factory setting. °5-507 RDS/CSS Alarm Level for Supplies (Supply Alarm Mode Setting) † Used in Japan only. Do not change the factory setting. 4-31 FT5535/4527/4522...
  • Page 83 Press the "Clear/mode" key to delete the input telephone number. °5-816 RDS/CSS Function Setting † For use in Japan only. Do not change the factory setting. 5-817 Repair Time Transmission † For use in Japan only. Do not change the factory setting. FT5535/4527/4522 4-32...
  • Page 84 (default) 2: Single side copy mode • °6-001 SADF Auto Sets the auto reset time for SADF mode. 1 ~ 99 Reset Time (1 second per step [range: 1 to 99 seconds]) Default = 5 Setting † 4-33 FT5535/4527/4522...
  • Page 85 APS priority (SP5-003) is set to Manual. • °6-011 Thick/Thin Selects the original feed type for the DF. 0: Thick mode Original Mode In thin mode, originals will not be pushed back 1: Thin mode Selection † against the left scale. FT5535/4527/4522 4-34...
  • Page 86 °7-001 Total Operation Displays the total operation time (hours). Time Display † The first three digits are displayed in the reduce/enlarge indicator. Hold down the " " • key to display the last three digits. 4-35 FT5535/4527/4522...
  • Page 87 °7-203 Drum Counter † Displays the drum rotation time (hours). The first three digits are displayed in the reduce/enlarge indicator. Hold down the " " • key to display the last three digits. FT5535/4527/4522 4-36...
  • Page 88 The service call code is displayed in the copy counter indicator, and the number of times this SC code has occurred is displayed in reduce/enlarge indicator. By pressing the keys, another service call number and its counter can be displayed. 4-37 FT5535/4527/4522...
  • Page 89 Displays the total original jams in the DF by Jams by location (max. 4 digits). Location † SP7-505-001: Feed-in section 7-505-002 SP7-505-002: Feed-out section The first digit is displayed in the reduce/enlarge indicator. Hold down the " " • key to display the last three digits. FT5535/4527/4522 4-38...
  • Page 90 " " key • to display the last three digits. °7-804 PM Counter Resets the PM counter. Clear The counter will be reset when you press the final key when entering this SP mode. 4-39 FT5535/4527/4522...
  • Page 91 Total Counter of Copy Paper SP7-504 Jams for Each location Total Counter of Original SP7-505 Paper Jams for Each location PM Counter SP7-803 After pressing the final key when entering this SP mode, the counters will be reset. FT5535/4527/4522 4-40...
  • Page 92 7-816-008 Without With SP Number Duplex Duplex SP7-816-001 1st tray — SP7-816-002 2nd tray 1st tray SP7-816-003 3rd tray 2nd tray SP7-816-004 4th tray 3rd tray SP7-816-005 5th tray 4th tray SP7-816-006 SP7-816-007 By-pass By-pass SP7-816-008 — Duplex 4-41 FT5535/4527/4522...
  • Page 93 6-002 ADF Free Size Setting 6-011 Thick/Thin Original Mode Selection 5-402 User Code Counter Check 5-404 User Code Counter Clear 5-405 User Code Number Setting 5-407 User Code Number Clear 5-001 All Indicators On 4-902 APS 8K/16K Detection FT5535/4527/4522 4-42...
  • Page 94 1st Tray Upper Limit Sensor Down (Paper Tray Unit) 1st Tray Set Sensor Not set (Paper Tray Unit) 2nd Tray Paper End Sensor Paper detected Paper not detected (Paper Tray Unit) 2nd Tray Upper Limit Sensor Down (Paper Tray Unit) 4-43 FT5535/4527/4522...
  • Page 95 Bin Lift Timing-2 Sensor (A554 only) Jogger H.P. Sensor (A554/A556) Grip H.P. Sensor (A554/A555) Staple H.P. (A554/A555) Staple End Switch Staple Paper Sensor Sorter Stapler Set SW. Front Door Door Closed Door Open SW (A554) Door Safety SW (A554) FT5535/4527/4522 4-44...
  • Page 96 A4/A3 Version Side Fence Position Displayed Number 11" A4 (lengthwise) B5 (lengthwise) A5 (lengthwise) B6 (lengthwise) LT/DLT Version Side Fence Position Displayed Number 11" " 8" " 4-45 FT5535/4527/4522...
  • Page 97 Lower tray separation SOL Lower tray pick-up SOL Lower tray lift motor (up) Lower tray lift motor (down) LCT pick-up SOL (LCT Equipped Units Only) Not used Not used LCT display Bin drive motor up Bin drive motor down FT5535/4527/4522 4-46...
  • Page 98 Quenching lamp, PTL Toner supply CL Development CL Toner supply bottle motor ADF feed-in motor ADF feed-in motor (reverse) ADF belt drive motor ADF belt drive motor (reverse) ADF feed-out motor ADF inverter SOL + Entrance SOL ADF display on 4-47 FT5535/4527/4522...
  • Page 99 Depending on the 3rd level program number, the paper tray indicator changes. • SP settings for each 3rd level program number are blinking in the reduce/enlarge indicator. *SPECIAL: See section 2.7.2 "Special Paper Size Selection for the 1st Tray". FT5535/4527/4522 4-48...
  • Page 100 Paper size SP settings for the LCT SP Settings A4 Version LT Version — — 11" x 8 " 11" x 8 " A4 (sideways) A4 (sideways) 5. Leave SP mode by pressing the "Clear Modes" key three times. 4-49 FT5535/4527/4522...
  • Page 101 10" x 14" 8" x 10 " 8" x 10" 225 mm x 276 mm 250 mm x 300 mm 8K (267 mm x 390 mm/lengthwise) 16K (267 mm x 195 mm/sideways) 16K (195 mm x 267 mm/lengthwise) FT5535/4527/4522 4-50...
  • Page 102 1: –40V, 2: ±0V, 3: –80V, 4: –120V SP2-201-002 Lightest ID Level Development Bias (ID Level 7) NOTE: After adjusting the Lamp Voltage, be sure to perform the Auto ADS Gain Adjustment (SP4-201) and the Forced V Detection (SP3-105). 4-51 FT5535/4527/4522...
  • Page 103 Total Jams by Location 5-402 User Code Counter 7-505 Total Original Jams by Location 5-408 Number of Registered User Codes 7-801 Main ROM Version 7-001 Total Operation Time 7-803 PM Counter 7-002 Total Original Counter 7-003 Copy Charge Counter for RDS/CSS FT5535/4527/4522 4-52...
  • Page 104 Auto image density sensor output TP15 (RXA) TP16 (CHA-FB) Drum charge roller feed-back voltage TP17 (DEV-BIAS) Development bias feed-back voltage TP18 — Drum charge thermistor output TP19 — Not used TP20 — Secondary fusing thermistor output TP21 — Main fusing thermistor output 4-53 FT5535/4527/4522...
  • Page 105 Blower brush PAPER FEED (for each paper feed station) Pick-up, Feed, Separation Clean with water. Replace Rollers (Paper tray) these rollers as a set. Pick-up, Feed, Separation Clean with water. Replace Rollers (LCT,By-pass feed) these rollers as a set. FT5535/4527/4522 4-54...
  • Page 106 Replace if necessary Fusing Exit Rollers Turn Guide Transport Rollers 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 4-55 FT5535/4527/4522...
  • Page 107 (LCT, By-pass feed) these rollers and the torque limiter as a set. Paper Feed Guide Plate Alcohol or water Relay rollers Alcohol or water Registration roller Alcohol or water Bottom Plate Pad (Paper Water tray, By-pass feed, LCT) FT5535/4527/4522 4-56...
  • Page 108 OTHERS Drive Belts Replace if necessary PAPER TRAY UNIT (A553) Feed Rollers Water Relay rollers Alcohol or water Bottom Plate Pad Water Paper Feed Guide Plate Alcohol or water Sensors Replace if necessary Drive Belts Replace if necessary 4-57 FT5535/4527/4522...
  • Page 109 Bushings Launa oil; if bushings generate noise. Helicam Wheels Grease G501; if helicam wheels generate noise. SORTER (A556/A557) Bin Guide/Wheel Grease G501; if those generate noise. Bushings Grease G501; if bushings generate noise. Exit Roller Alcohol or water FT5535/4527/4522 4-58...
  • Page 110 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 FT5535/4527/4522...
  • Page 111 Discharge any static electricity before putting them back. Replace the 4. Put back the drum. pick-off pawls (every 200/240k). 5. Replace the drum charge roller, drum charge roller cleaner, and drum charge roller terminal and roller terminal. FT5535/4527/4522 4-60...
  • Page 112 Replace the pick-up, 4. Clean the registration rollers. feed, and separation rollers for each paper feed station, by-pass feed, and the LCT (every 200/240k). Replace the separation torque limiter for the by-pass feed station and the LCT (every 200/240k). 4-61 FT5535/4527/4522...
  • Page 113 2. Replace the feed roller and the bottom plate pad. 9. Duplex Tray (every 100 or 120 k) 3. Lubricate the clutch spring with Mobil Temp 1. Inspect the timing belts. 10. Rear of the machine (every 100 or 120 k) FT5535/4527/4522 4-62...
  • Page 114 5. SP4-201 Auto ADS Gain Adj. 6. * SP3-105 Forced V Detection *: Perform these SP modes only if the exposure lamp has been replaced. Make a copy of an OS-A3 test chart at manual 13. Make a Copy image density level 4. 4-63 FT5535/4527/4522...
  • Page 115 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 5447 9078 Heat Resistant Grease - MT-78 5203 9501 Grease - 501 FT5535/4527/4522 4-64...
  • Page 116 SECTION 5 REPLACEMENT AND ADJUSTMENT...
  • Page 117 1. Open the front cover and pull out the paper trays [C]. 2. Remove the left cover [D] (2 screws). - A157/A159/A160 - 1. Open the front cover and pull out the paper trays. 2. Remove the cover plate [E] (2 screws). 3. Remove the left cover [F] (4 screws). FT5535/4527/4522...
  • Page 118 2. Open the front cover and slide out the toner bottle holder assembly [F] (1 screw and 1 knob screw). 3. Remove the operation panel [G] (4 screws and 2 connectors). NOTE: For the A156 copier, remove 5 screws and 3 connectors. FT5535/4527/4522...

  • Page 119: Inner Cover Removal

    3. Remove the lower right inner cover [G] (1 screw). 1.2.3 Lower Left Inner Cover 1. Remove the front cover and open the tray units. 2. Remove the lower left inner cover [H] (2 screws). FT5535/4527/4522...
  • Page 120 NOTE: Do not touch the reflector or the new exposure lamp with your bare hands. Use a strip of paper as shown. (Oil marks from fingers on the lamp or reflectors will be affected by heat from the lamp and will cause discoloration.) FT5535/4527/4522...
  • Page 121 NOTE: If an FT4022/4522(A161/A162) lamp is installed in a FT4027/4527 (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. FT5535/4527/4522...
  • Page 122 3. Remove the main control board bracket (4 screws), and remove the C/B high voltage supply board assembly [I] (2 screws, 3 connectors and 1 clamp). 4. Loosen the screws securing the belt tension brackets [J] and remove all four belt tension springs as shown. FT5535/4527/4522...
  • Page 123 7. Remove the left scale bracket [C] with the optics thermistor (2 screws and 1 connector). 8. Remove the scanner home position sensor bracket [D] (1 screw and 1 connector). 9. Remove the lens housing cover [E] (2 screws). 10. Remove both scanner guide rails [F] (1 spring plate each). FT5535/4527/4522...
  • Page 124 • The belt tension bracket should be tightened after all the belt tension springs have been installed. • Adjust the position of the 1st and 2nd scanner by using the positioning bracket kit. (See Scanner Positioning Adjustment.) FT5535/4527/4522...
  • Page 125 4. Manually set the 1st [C] and 2nd [D] scanner on the pins of the scanner positioning bracket as shown. 5. Tighten the belt clamps. NOTE: To remove the scanner positioning brackets, gently lift up both scanner units and move them towards the home position. 6. Reassemble the machine and check the copy quality. FT5535/4527/4522...
  • Page 126 5. Remove the front scanner guide rail [D] (1 spring plate). 6. Remove the 2 idle gears [E] (1 E-ring). 7. Remove the 3rd scanner motor bracket [F] (2 screws and 1 connector). 8. Replace the 3rd scanner motor [G] (2 screws). FT5535/4527/4522 5-10...
  • Page 127 1. Place the bead [E] in the slot [F] and wind the drive wire four and a half times around the pulley [G]. 2. Wrap the wire around the wire pulley [H] and attach the spring [A] to the bracket. 5-11 FT5535/4527/4522...
  • Page 128 5. Remove the knob screw [E] and disconnect the connector [F]. 6. Press down the development unit lock lever [G] and pull out the development unit [H]. Then place it on a clean sheet of paper. FT5535/4527/4522 5-12...
  • Page 129 3. Turn over the development unit and empty all the developer [C] onto the sheet [D]. Make sure that no developer remains on the development roller or in the unit. NOTE: Dispose of the used developer in accordance with local regulations. 5-13 FT5535/4527/4522...
  • Page 130 7. Turn on the main switch, then perform the TD sensor initial setting for new developer using SP2-214. CAUTION Never make any copy with the new developer before completing the TD sensor initial setting (SP2-214). Otherwise toner density control will be abnormal. FT5535/4527/4522 5-14...
  • Page 131 8. Remove the toner supply motor bracket [E] (1 screw) and replace the toner supply motor [F] (1 E-ring and 1 gear shaft). NOTE: When reinstalling the hinge bracket on the bottle holder, make sure that the roller [G] slides into the notch [H] between the two guide rails as shown. 5-15 FT5535/4527/4522...
  • Page 132 Doing so prevents the drum charge roller from sticking to the drum. Also, the paper protects the drum from light fatigue. 2. Place the drum unit on a clean sheet of paper. FT5535/4527/4522 5-16...
  • Page 133 2) Do not bend the bearing holder. Make sure the bearing holder is in contact with the bearing, as they are both used to ground the unit. If they are not in contact, solid black copies may occur. 5-17 FT5535/4527/4522...
  • Page 134 NOTE: Before reinstalling the drum charge roller assy on the drum unit, be sure that no setting powder remains on the drum. If setting powder gets onto the drum charge roller, copy quality problems will occur. 11. Refer to Section 4 page 4-11 for Drum Initialization Procedures. FT5535/4527/4522 5-18...
  • Page 135 3. Remove the recycled toner transport coil ass’y [B] (2 screws). 4. Remove the shaft [C] (one E-ring and two gears). 5. Remove the pick-off pawl ass’y [D] while sliding it sideways. 6. Remove the pick-off pawls [E] (one shaft [F]). 5-19 FT5535/4527/4522...
  • Page 136 [E]. 5. Remove the other end of ID sensor board [F] from the holder [G] while rolling the ID sensor board in the direction of the arrow as shown in the diagram. 6. Remove the ID sensor board. FT5535/4527/4522 5-20...
  • Page 137 NOTE: 1. Check that there is no dust on the edge of the new cleaning blade. 2. When installing the new cleaning blade, be sure not to deform the sponge seal [F] at both sides of the cleaning blade holder. 5-21 FT5535/4527/4522...
  • Page 138 8. Reinstall the drum charge roller ass’y on the drum unit (2 screws, 1 connector). NOTE: Before reinstalling the drum charge roller ass’y on the drum unit, be sure that no setting powder remains on the drum. If setting powder gets onto the drum charge roller, copy quality problems will occur. FT5535/4527/4522 5-22...
  • Page 139 NOTE: This step prevents the PTL board from damaging the transfer belt if it falls. 3. Remove the screw [B] and push the PTL board [C] halfway in from the front until its front end does not fall down. 4. Remove the PTL board [C] from the back of the copier. 5-23 FT5535/4527/4522...
  • Page 140 3. Disconnect the connector [B] (CN108) from the main board. 4. Remove the screw [C] and push the quenching lamp [D] halfway in from the front until its front end does not fall down. 5. Remove the quenching lamp [D] from the back of the copier. FT5535/4527/4522 5-24...
  • Page 141 3. Remove the screw [B] and push the erase lamp [C] halfway in from the front until its front end does not fall down. 4. Remove the erase lamp [C] from the back of the copier. 5-25 FT5535/4527/4522...
  • Page 142 2. If there is any dirt on the surface of drum charge roller, wipe it off with a dry cloth or a special cloth for the drum charge roller. (The special cloth is available as a service part: A1539004) Never use alcohol or water to clean the drum charge roller. FT5535/4527/4522 5-26...
  • Page 143 A1539004.) Never use alcohol or water to clean the drum charge roller. 3. When replacing the drum charge roller terminal [B], replace also the roller terminal [C] at the same time. 5-27 FT5535/4527/4522...
  • Page 144 4.11 DRUM CHARGE ROLLER CLEANER REPLACEMENT 1. Remove the drum charge roller ass’y. 2. Remove the screw [A]. 3. Pull out the drum charge roller cleaner [B]. FT5535/4527/4522 5-28...
  • Page 145 When reinstalling the transfer belt unit, align gear [D] and opening [E]. A157, A159, and A160 copiers: When reinstalling the transfer belt unit, align opening [F] and positioning pin [G] first. Then align gear [H] and opening [I]. 5-29 FT5535/4527/4522...

  • Page 146: Transfer Belt Replacement

    4. Remove the screws [E] and turn the belt drive holder [F]. 5. Replace the transfer belt [G]. NOTE: Be careful not to bend the high voltage terminal [H]. 6. Position the transfer belt at the center of the belt roller [I]. (Both marks [J] should be visible.) FT5535/4527/4522 5-30...
  • Page 147 6. Rotate the gear [C] clockwise to apply the setting powder evenly to the edge of the transfer belt cleaning blade. 7. Do steps 5 and 6 two or three times. NOTE: Steps 5 and 6 prevent the transfer belt cleaning blade from catching the transfer belt. 5-31 FT5535/4527/4522...
  • Page 148 2. Open the cap [A] and pour the collected toner slowly onto a sheet of paper so that the toner does not scatter. NOTE: Never use the collected toner in the transfer belt unit for toner recycling. 3. Dispose of the toner in accordance with the local regulations. FT5535/4527/4522 5-32...
  • Page 149 2. Remove the pick-up [C] and feed [D] rollers, torque limiter [E], and the separation roller [F] (1 clip each). NOTE: After reinstalling the paper feed tray, perform the side-to-side registration adjustment (see Side-to-side Registration Adjustment). 5-33 FT5535/4527/4522...
  • Page 150 8. Remove the spring [E] and remove the timing belt [F] from the relay roller pulley [G]. 9. Remove the vertical transport guide plate [H] (1 screw). 10. Remove the paper feed unit [I] (2 screws, 1 connector). FT5535/4527/4522 5-34...
  • Page 151 4. Remove the relay clutch [C] (1 connector, 1 bushing). 5. Remove the upper paper feed clutch [D] (1 E-ring, 1 connector). 6. Remove the separation roller drive gear [E] (1 E-ring). 7. Remove the upper paper feed unit [F] (2 screws, 1 connector). 5-35 FT5535/4527/4522...
  • Page 152 4) Roller position [b] is only used in Japanese models. 4) Roller position [c] is especially useful for B size paper. When paper jam or non-feed occurs often with B size paper, change the feed roller position to [c]. FT5535/4527/4522 5-36...
  • Page 153 2. Remove the lower right inner cover (see "Inner Cover Removal"). 3. Remove the transfer belt assembly (see "Transfer Belt Unit Removal"). 4. Remove the registration sensor bracket [A] (1 screw, 1 connector). 5. Remove the registration sensor [B]. 5-37 FT5535/4527/4522...
  • Page 154 2. Remove the rear cover (see "Outer Cover Removal"). 3. Remove the paper feed clutch assembly [A] (3 screws, 1 connector). 4. Remove one E-ring [B] and the pull out the shaft [C]. 5. Remove the paper feed clutch [D] (1 connector). FT5535/4527/4522 5-38...
  • Page 155 2. Remove the harness cover [A] (1 screw). 3. Remove the LCT’s rear cover [B] (2 screws). 4. Remove the stopper bracket [C] (1 screw). 5. Disconnect five connectors [D] and remove the harness bushing [E]. 6. Remove the LCT. 5-39 FT5535/4527/4522...
  • Page 156 6. Remove the belt stoppers [F] (1 screw each). 7. Remove the upper pulley [G] and LCT drive belt [H] (1 E-ring each). NOTE: When reinstalling the belt stoppers, make sure that the LCT bottom plate is at the bottom. FT5535/4527/4522 5-40...
  • Page 157 7.3 LCT MOTOR REPLACEMENT 1. Remove the LCT (see "LCT Unit Removal"). 2. Remove the vertical transport guide [A] (4 screws). 3. Remove the LCT motor [B] (3 screws, 1 connector). 5-41 FT5535/4527/4522...
  • Page 158 3. Hold the fusing unit cover [B] while pushing the release lever [C] to the left, and pull out the fusing unit until it stops. 4. Push the release lever again, and remove the fusing unit completely. CAUTION Before completely removing the fusing unit, support the bottom of the fusing unit. FT5535/4527/4522 5-42...
  • Page 159 NOTE: 1) Do not touch the fusing lamps with bare hands. 2) When reinstalling the rear lamp holder, make sure that the antistatic brush [J] contacts the hot roller and pressure roller shown. 3) The standard pressure spring position is at the upper position. 5-43 FT5535/4527/4522...
  • Page 160 A157/159/160. To distinguish between the two types of hot roller, look at the end of the roller. The A153/155/156 roller has three small dot-like indentations at one end, and the A157/159/160 has two. Do not confuse the two, or the machine may be damaged. FT5535/4527/4522 5-44...
  • Page 161 (for standard or thin paper). For thick paper, let the entrance guide plate drop to the lowest position. 2) The standard pressure spring position is at the upper position. 5-45 FT5535/4527/4522...
  • Page 162 2. Remove the pressure springs and remove the upper fusing unit (4 screws). 3. Remove the thermofuse [A] (2 screws). NOTE: 1) When replacing the thermofuse, make sure that you do not damage the hot roller. 2) The standard pressure spring position is at the upper position. FT5535/4527/4522 5-46...

  • Page 163: Duplex Unit

    3. Remove the springs [B]. 4. Remove the friction roller [C] (2 E-rings, 2 bushings). NOTE: This friction roller has a one-way clutch. Be sure to install the roller so that it rotates in the direction of the arrow (see the illustration). 5-47 FT5535/4527/4522...
  • Page 164 7. Remove the bushing [F], the paper flattener [H] (1 E-ring), the stack roller [I], the paper flattener [J], and the duplex feed roller [K]. NOTE: When installing the stack roller and the duplex feed roller, make sure that they are inserted in the correct orientation as shown. FT5535/4527/4522 5-48...
  • Page 165 4. Remove the inner cover [D] (1 screw). 5. Remove the inner cover bracket [E] (1 screw). 6. Remove the duplex feed roller assembly [F] (2 clips). 7. Remove the timing belt pulley [G] and remove the timing belt [H]. 8. Remove the spring [I]. 5-49 FT5535/4527/4522...
  • Page 166 [E] is on top of the bracket [F] as shown. 2) When installing the paper feed assembly, make sure that the mylar [G] on the bottom plate is on top of the guide plate [H] as shown. FT5535/4527/4522 5-50...

  • Page 167: Copy Quality Adjustment

    3. Place an OS-A3 chart on the exposure glass. 4. Make a full size copy at manual image density level 4 (center) after the copier has warmed up. 5. Check that level 2 of the gray scale is just visible on the copy. 5-51 FT5535/4527/4522...
  • Page 168 4) Check whether the image density is correct or not. If it is not, repeat the above steps from (1) to (3). 7. Perform ADS gain adjustment (SP4-201) and forced V detection (SP3-105). NOTE: If the image density cannot be adjusted satisfactorily, adjust the development bias using SP2-201-001 (see section 10-3). FT5535/4527/4522 5-52...
  • Page 169 3. If the side-to-side variation of the gray scales is not within the adjustment standard, turn off the main switch and remove the exposure glass (see Exposure Glass Removal). 4. Position the adjusting plates [A] so that the copy quality meets the adjustment standard. 5-53 FT5535/4527/4522...
  • Page 170 Setting Density Correction Voltage Dark +80V +60V +40V +20V ± 0V Normal –20V –40V –60V Light –80V 1. Enter SP2-201-001. 2. Change the setting displayed in the reduce/enlarge indicator with the numeric keys. 3. Leave this SP mode. FT5535/4527/4522 5-54...
  • Page 171 Correction Voltage Normal –40V ± 0V Dark Lighter –80V Lightest –120V 1. Enter SP2-201-002. 2. Change the setting displayed in the reduce/enlarge indicator with the number keys. Determine the new setting from the above table. 3. Leave SP2-201-002. 5-55 FT5535/4527/4522...
  • Page 172 ± 0 Normal Normal –20V –40V –60V High Dark –80V 1. Enter SP2-203. 2. Change the setting displayed in the reduce/enlarge indicator with the numeric keys. Determine the new setting from the above table. 3. Leave this SP mode. FT5535/4527/4522 5-56...
  • Page 173 How: SP3-001 adjusts the value in memory for the ID sensor LED to get the correct sensor output. NOTE: The adjusted value and sensor output can be monitored with SP3-002. Refer to the SP mode table for details. 5-57 FT5535/4527/4522...
  • Page 174 All three service programs change the toner supply clutch ON period. SP2-222: Toner Supply Ratio (Detect Supply Mode) Setting Toner Supply Ratio SP2-208-002: Toner Supply Ratio (TD Sensor Supply Mode) Setting Toner Supply Ratio SP2-208-003: Toner Supply Ratio (Fixed Supply Mode) Setting Toner Supply Ratio FT5535/4527/4522 5-58...
  • Page 175 Purpose: To maintain good copy quality in ADS mode. How: Use SP5-106. For example, for lighter copies, select the "2: Light" setting (this increases the negative development bias voltage). SP5-106: ADS Density 0: Dark 1: Normal 2: Light 5-59 FT5535/4527/4522...
  • Page 176 NOTE: SP4-008 can be set between 0 and 32. Vertical magnification changes 0.1% per step. 3) Leave the SP mode. 4) Check whether vertical magnification is correct or not. If it is not, repeat the above steps from (1) to (3). FT5535/4527/4522 5-60...
  • Page 177 NOTE: SP4-101 can be set between 0 and 32. Horizontal magnification changes 0.1% per step. 3) Leave SP mode. 4) Check whether horizontal magnification is correct or not. If it is not, repeat the above steps from (1) to (3). 5-61 FT5535/4527/4522...
  • Page 178 To maintain proper lead edge registration. 0 ± 2 mm (0 ± 0.08") Adjustment standard: How: SP1-101 changes the registration roller start timing. SP1-101: Registration 0 - 32 (default = 16, – 8.0 mm to + 8.0 mm), 0.5 mm per step FT5535/4527/4522 5-62...
  • Page 179 Use this if the image shift direction (to the front or to the rear) is the same from all paper feed stations. 1. Make a full size copy from each paper feed station. 2. Check whether side-to-side registration is within the adjustment standard. 5-63 FT5535/4527/4522...
  • Page 180 If the copy image is shifted to front, increase the setting If the copy image is shifted to rear, decrease the setting 4) Leave SP mode. 5) Check whether side-to-side registration is correct or not. If it is not, repeat the above steps from (1) to (4). FT5535/4527/4522 5-64...
  • Page 181 1. Turn off the main switch and remove the exposure glass. 2. Peel off the shielding mylar [A] halfway. 3. Adjust the 4th/5th mirror height by turning the adjusting screw [B]. NOTE: After the adjustment, stick the mylar [A] again in its former position. 5-65 FT5535/4527/4522...
  • Page 182 1. Turn off the main switch and unplug the power cord. 2. Remove the rear cover. 3. Remove the main control board [A] (4 screws and all connectors). 4. Remove the RAM board [B] from the old main control board and install it on the new board. FT5535/4527/4522 5-66...
  • Page 183 2. Do not adjust VR371 on the ac drive board. Copy quality will be seriously affected if it is turned. 1. Turn off the main switch and unplug the machine. 2. Remove the rear cover. 3. Replace the ac drive board [A] (1 screw, 3 locking supports, and all connectors). 5-67 FT5535/4527/4522...
  • Page 184 1. Turn off the main switch and unplug the machine. 2. Remove the rear cover. 3. Replace the dc power supply board [A] (7 screws and all connectors). NOTE: 6 screws for 115V machines. FT5535/4527/4522 5-68...
  • Page 185 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). 5-69 FT5535/4527/4522...
  • Page 186 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). FT5535/4527/4522 5-70...
  • Page 187 SECTION 6 TROUBLESHOOTING...

  • Page 188: Pcb1

    334 mm/13.15" (A153, A155, and A156 copiers) Transfer Belt 244.5 mm/9.63" (A157, A159, and A160 copiers) 125.6 mm/4.94" Hot Roller or Pressure Roller 2. If the problem is related to electrical circuit boards, first disconnect, then reconnect the connectors before replacing the PCBs. FT5535/4527/4522...
  • Page 189 The drum was exposed to fluorescent light or direct sunlight for long period • of time The drum was exposed to ammonia gas or corrosive fumes for a long • period of time 5. The drum does not rotate. FT5535/4527/4522...
  • Page 190 Does the development unit drive clutch turn on properly? Does the voltage at CN117-4 stay at 24 volts on the main board after the Start key is pressed? 24 volts 0 volts Replace the development unit drive clutch. Replace the main control board. FT5535/4527/4522...
  • Page 191 5V pulse signal, replace the T high voltage supply board. If there is no problem with the signal lines, replace the drum if the sensitivity does not recover even when the drum is not exposed to light. FT5535/4527/4522...

  • Page 192: Dirty Background

    Improper setting of the drum charge voltage adjustment (SP2-001) • Improper V pattern bias (SP2-203) • Dirty erase lamp unit • 6. Drum charge roller thermister error Connector of the drum charge roller thermistor id not connected properly. • Broken drum charge roller thermistor • FT5535/4527/4522...
  • Page 193 SP3-801 set to ON? b) Is initial V (SP3-106) not 0? Clean the optics and adjust the exposure lamp voltage (SP4-001) Perform ADS initial setting (SP4-201) and forced V detection (SP3-105) Set SP3-801 to 1 Perform forced V detection (SP3-112) FT5535/4527/4522...
  • Page 194 Check the continuity between the development roller shaft and the development bias terminal Good No good Repair the harness or terminals. Is the signal at CN115-1 a 5V pulse signal after the Start key is pressed? Replace the main control board. Replace the CB high voltage supply board. FT5535/4527/4522...
  • Page 195 If dirty background occurs only for some types of red paper originals in ADS mode, do the following: Change the ADS sensor to the optional ADS sensor which has different • sensitivity for red paper originals. See "ADS SENSOR (OPTION)" in Section 3. FT5535/4527/4522...
  • Page 196 Adjust the exposure adjustment plates on the 1st scanner. (See Uneven Exposure Adjustment in the Replacement and Adjustment section.) Is the erase lamp, quenching lamp, or toner shield glass dirty? Clean the erase lamp, quenching lamp, or toner shield glass. Clean or replace the drum charge roller. FT5535/4527/4522...
  • Page 197 Replace the cleaning blade. Is the drum charge roller dirty ? Clean or replace the drum charge roller. If the inlet seal on the development unit is deformed, replace the inlet seal plate and the seal as a set. FT5535/4527/4522 6-10...

  • Page 198: Vertical Black Lines

    Wipe again with a dry cloth Wipe with a dry cloth with water (until no water remains) NOTE: Never use alcohol to clean the drum, alcohol dissolves the drum surface. If the drum is scratched, replace the drum. • 6-11 FT5535/4527/4522...
  • Page 199 Clean the drum charge roller with a dry cloth. Is the inlet seal damp or deformed. Clean the inlet seal with a dry cloth. If the problem is not corrected, replace the inlet seal plate and the seal as a set. Replace the drum charge roller. FT5535/4527/4522 6-12...
  • Page 200 NOTE: If the drum is scratched, find out what caused the scratches on the drum and correct the problem. It could be any of the following. Paper misfeed • Incorrect positioning of the pick-off pawls • Foreign substances on the cleaning blade • Carrier leakage • 6-13 FT5535/4527/4522...
  • Page 201 Is the drum charge roller scratched ? Replace the drum charge roller. Is the hot roller scratched? Replace the hot roller. If toner adheres to the drum surface, clean the drum with wet cotton. Also clean or replace the cleaning blade. FT5535/4527/4522 6-14...
  • Page 202 Reposition the mirror correctly. If the spring plates are defective, replace them. Are the stubs of the 3rd scanner assembly off the rails? Put the scanner assembly stubs back on the rails. Readjust the height of the 3rd scanner by turning the adjusting screw. 6-15 FT5535/4527/4522...
  • Page 203 Clean the ID sensor and around the drum including the development unit. Adjust the ID sensor with SP3-001. Can the ID sensor be adjusted correctly? Refer to the section dealing with SC351. Enter SP3-103-001 (displays the value of V ) and make sky-shot copies until becomes about 0.4 V. FT5535/4527/4522 6-16...
  • Page 204 The toner supply clutch should turn on for about a second or a second and a half at intervals that depend on the condition of the developer. The toner supply clutch should not remain on for long periods, switch on/off erratically, or stay on permanently. 6-17 FT5535/4527/4522...
  • Page 205 Adjust the ID sensor with SP3-001. Can the ID sensor be adjusted correctly? Refer to the section that deals with SC351. Perform forced toner supply (SP2-207) until V is at about the threshold level (around 0.4 V). Check V with SP3-103-001 as necessary. FT5535/4527/4522 6-18...
  • Page 206 SP2-003. If it is not, then store 16 in SP2-003. Is the copier in fixed supply mode? Change the setting of SP2-208-001 to "3". Increase the value of the development bias correction for making V patterns (SP2-203) to make the V pattern lighter. 6-19 FT5535/4527/4522...
  • Page 207 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". Is the inlet seal deformed? Replace the inlet seal plate. Replace the developer. FT5535/4527/4522 6-20...
  • Page 208 Adjust the position of the pressure springs to increase the fusing pressure. No good Increase the fusing temperature using SP1-105-001 (main fusing lamp) and SP- 105-003 (secondary fusing lamp). No good Check the thermistor. If the thermistor is malfunctioning, replace it. 6-21 FT5535/4527/4522...
  • Page 209 The variation in leading edge registration is too big. - Action - Adjust the amount of paper buckle between the registration rollers and the feed & separation rollers with SP1-003 for each paper feeding station. See the SP mode table for details. FT5535/4527/4522 6-22...
  • Page 210 Check whether the ID sensor board terminal contacts the connector at the rear of the copier well or not. Good No Good Clean the ID sensor board terminal and make it contact the sensor fully. Replace the ID sensor board. 6-23 FT5535/4527/4522...
  • Page 211 Replace the ID sensor board. Is the TD sensor initial setting (SP2-220) within the 2.5 ± 0.1 V range? Is the TD sensor connector connected properly? Connect the TD sensor connector. Replace the developer and do the TD sensor initial setting (SP2-214). FT5535/4527/4522 6-24...
  • Page 212 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. 6-25 FT5535/4527/4522...

  • Page 213: Service Call Conditions

    Lens horizontal home position sensor error 2 E144 3rd scanner home position sensor error 1 E145 3rd scanner home position sensor error 2 E191 Auto ID sensor adjustment error E302 Drum charge roller current leak E346 Development bias leak E351 ID sensor adjustment error FT5535/4527/4522 6-26...
  • Page 214 Sorter timing sensor (roller drive) output error E721 Sorter timing sensor (bin lift) output error E722 Sorter jogger h.p. sensor output error E723 Sorter grip h.p. sensor output error E724 S/S stapler error E900 Total counter error 1 E901 Total counter error 2 6-27 FT5535/4527/4522...
  • Page 215 NOTE: (1) A153/A155 copiers only (2) A153/A155/A156 copiers only (3) When a paper tray unit (500×2, 500×3) is installed (4) When a paper tray unit is installed (5) LCT machines only (6) A156/A160 copiers only FT5535/4527/4522 6-28...
  • Page 216 Message on LCD (A156 copier only) Key counter not set Insert a key counter or enabling device/ Enter a user code Fusing unit not set Open the front cover and reset the fusing unit Duplex unit not set Insert the duplex unit 6-29 FT5535/4527/4522...
  • Page 217 The scanner home position sensor remains actuated for 0.5 seconds after the scanner starts. - Possible causes - • Scanner home position sensor failure • Defective scanner drive motor • CN114 on the main control board not connected correctly • Incorrect scanner wire position FT5535/4527/4522 6-30...
  • Page 218 The lens horizontal home position sensor remains de-actuated 3.7 seconds after the lens starts returning to the home position. - Possible Causes - • Lens horizontal home position sensor defective • Lens horizontal drive motor defective • DC power supply board defective (check FU303) 6-31 FT5535/4527/4522...
  • Page 219 The 3rd scanner home position sensor remains actuated 3.7 seconds after the 3rd scanner left the home position. - Possible Causes - • 3rd scanner home position sensor defective • 3rd scanner drive motor defective • DC power supply board defective (check FU303) FT5535/4527/4522 6-32...
  • Page 220 When the ID sensor output (V ) falls out of the adjustment target (3.8 ~ 4.2 V) during the process control self check. - Possible Causes - • ID sensor board defective • Dirty ID sensor • Main control board defective 6-33 FT5535/4527/4522...
  • Page 221 E355: TD sensor upper limit detection abnormal - Definition - [D] TD sensor output exceeds 4.0 volts during copy cycles. - Possible Causes - • TD sensor defective • Main control board defective • Toner supply system defective FT5535/4527/4522 6-34...
  • Page 222 E442: Drum charge thermistor abnormal - Definition - [D] The temperature detected by the drum charge thermistor drops below 0 °C or rises above 100 °C. - Possible Causes - • Drum charge thermistor open • Main control board defective 6-35 FT5535/4527/4522...
  • Page 223 The LCT upper limit sensor is not actuated after the LCT lift motor has been on for 15.0 seconds. - Possible Causes - • LCT upper limit sensor defective • LCT lift motor defective • LCT interface board defective • Main control board defective FT5535/4527/4522 6-36...
  • Page 224 5.0 seconds when the jogger home position initialization procedure is performed. - Possible Causes - • Side fence jogger home position sensor defective • Side fence jogger motor defective • Duplex control board defective • Main control defective 6-37 FT5535/4527/4522...
  • Page 225 - Definition - [A] A fusing temperature of over 230 °C is detected 5 times (this takes 5 seconds). - Possible Causes - • Fusing thermistor defective • AC drive board defective (check the triac) • Main control board defective FT5535/4527/4522 6-38...
  • Page 226 - Definition - [C] The main CPU cannot start communication with the ARDF properly. - Possible Causes - • Poor connection between the main control board and ARDF • Main control board defective • DF main board defective 6-39 FT5535/4527/4522...
  • Page 227 When the bin lift/bin drive motor is turning, the timing sensor takes over 250 ms to change. - Possible Causes - • The timing sensor is defective. • The bin lift/bin drive motor is defective. • The main control board is defective. FT5535/4527/4522 6-40...
  • Page 228 E724 - Stapler Error (A554/A555) - Definition- [C] The stapler motor takes more than 800 ms for one staple operation (from home position to home position). - Possible Causes - • The stapler is defective. • The main control board is defective. 6-41 FT5535/4527/4522...
  • Page 229 • Total counter defective • CN121 on the main control board not connected correctly E901: Total counter error 2 - Definition - [B] The total counter does not turn off. - Possible Causes - • Total counter defective FT5535/4527/4522 6-42...

  • Page 230: Blown Fuse Conditions

    C5 lights on machines that have a sorter installed. Also VAA3 the DF does not communicate with the copier (the DF stays off). AC Drive Board (for 115 V machines only) FU371 15 A/125 V — 115VAC No response 6-43 FT5535/4527/4522...
  • Page 231 LCT Paper End 129-7 Open The Paper End indicator lights even if there is paper in the LCT. [LCT machines only] (S10) Shorted The Paper End indicator does not light even if there is no paper. FT5535/4527/4522 6-44...
  • Page 232 E405 is displayed. Auto Image 114-2 Open The image density will be abnormal. Density [ADS Shorted Sensor] (S25) Original Width 119-2~5 Open The CPU cannot detect the original size properly. APS and ARE do not function (S26) Shorted correctly. 6-45 FT5535/4527/4522...
  • Page 233 E523 is displayed. HP [Duplex Shorted E522 is displayed. machines only] (S32) Original Length 118-7 Open The CPU cannot detect the original size properly. APS and ARE do not function [Option for N. Shorted correctly. American models] (S33) FT5535/4527/4522 6-46...
  • Page 234 "C1" is not displayed even if the front cover is opened. Exit Cover Safety 109-11 Open "C2" is displayed even if the front cover is closed. [A157/A159/A160 machines only] Shorted "C2" is not displayed even if the front cover (SW12) is opened. 6-47 FT5535/4527/4522...
  • Page 235 SECTION 7 DF61 AUTO REVERSE DOCUMENT FEEDER (Machine Code: A548)
  • Page 236 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) FT5535/4527/4522...
  • Page 237 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 FT5535/4527/4522...
  • Page 238 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 FT5535/4527/4522...

  • Page 239: Pcb10

    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. FT5535/4527/4522...
  • Page 240 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. Sponge Retainer............1 FT5535/4527/4522...
  • Page 241 7. Connect the connectors [G] into the socket on the rear of the copier. 8. All models except for the A156: Attach the symbol explanation decal [H] and the combine originals explanation decal [I] to the ARDF as shown. FT5535/4527/4522...
  • Page 242 A157/159/160. To make a free run 1. Set up dip switches 1 to 4 for the required free run mode the test begins automatically. 2. To stop the free run, put the dip switches back to 0. FT5535/4527/4522...

  • Page 243: Variable Resistors

    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. FT5535/4527/4522...
  • Page 244 NOTE: a) When installing the transport belt, make sure that the belt runs under the belt guide spacers [E]. b) When securing the transport belt assembly with the 6 screws, make sure to secure the four upper screws first. FT5535/4527/4522...
  • Page 245 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. FT5535/4527/4522 7-10...
  • Page 246 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 FT5535/4527/4522...
  • Page 247 5. Remove both front [D] and rear [E] feed-in cover magnet catches (1 screw each). 6. Remove the feed-in guide plate [F] (4 screws). 7. Remove the original set sensor assembly [G] (1 screw). 8. Remove the original width sensor assembly [H] (1 screw). 9. Replace the required sensor. FT5535/4527/4522 7-12...
  • Page 248 1. Perform steps 1 through 5 of the rough adjustment procedure. 2. If the gap is larger than 2.5 mm, adjust the registration with the copier SP mode for the DF Registration Adjustment in one-sided original mode. (Increasing the setting will increase the gap.) 7-13 FT5535/4527/4522...
  • Page 249 1. Perform steps 1 through 6 of the rough adjustment procedure. 2. If the gap is not within specification, adjust the registration with the copier SP mode for the DF Registration Adjustment in two-sided original mode. (Increasing the setting will increase the gap.) FT5535/4527/4522 7-14...
  • Page 250 7. Check the copy quality and adjust the ADF side-to-side registration with the copier SP mode if it is not within the 0 ± 2 mm specification (see Replacement and Adjustment - Side-to-side Registration Adjusment in the copier manual). 7-15 FT5535/4527/4522...
  • Page 251 SECTION 8 PS290/280 PAPER TRAY UNIT (Machine Code: A549/550)
  • Page 252 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) FT5535/4527/4522...
  • Page 253 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 FT5535/4527/4522...
  • Page 254 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 FT5535/4527/4522...
  • Page 255 Paper pick-up 3 (A549 SOL3 only) SOL4 Separation 1 Lifts/drops the separation roller SOL5 Separation 2 SOL6 Separation 3 Heaters Tray (Option) Turns on when the main switch is off to keep the paper in the trays dry Tray (Option) FT5535/4527/4522...
  • Page 256 1. Right Support Bracket............. 1 2. Left Support Bracket ............... 1 3. Joint Bracket ................1 4. Shoulder Screw ..............1 5. Screw - M4 x 8................ 4 6. New Equipment Condition Report .......... 1 7. Installation Procedure ............1 FT5535/4527/4522...
  • Page 257 Proper reinstallation of the shipping retainers is required in order to avoid any transport damage. 1. Remove the strips of tape. 2. Remove the bottom plate stopper [A]. FT5535/4527/4522...
  • Page 258 11. Enter the proper paper size for each paper tray by following the instructions in the copier’s manual. 12. Attach the appropriate tray decals [K] which are included in the accessory box of the main copier. 13. Check the machine’s operation and copy quality. FT5535/4527/4522...
  • Page 259 5. Install the heater bracket [G] (2 screws). 6. Connect the heater harnesses. 7. Install the clamper [H] and clamp the heater harnesses. NOTE: After replacing the paper tray, perform the side-to-side registration adjustment (see Removal and Adjustment in the manual for the copier). FT5535/4527/4522...
  • Page 260 (10 s) 1st feed station 2nd feed station 3rd feed station Repeat Two paper feed tray type Repeat Three paper feed tray type Free Run Mode 2 The paper feed operation can be checked for the selected paper feed station. FT5535/4527/4522...
  • Page 261 4.2 TEST POINTS NUMBER FUNCTION TP101 + 5V TP102 + 24V TP103 TP104 TXD (Transmit signal) TP105 RXD (Receive signal) TP106 FT5535/4527/4522 8-10...
  • Page 262 Right Rear Cover [D]: 1. Remove the rear cover [A]. 2. Remove the right rear cover (2 screws). Left Cover [E]: 1. Remove the rear cover [A]. 2. Remove the front lower cover [B]. 3. Remove the left cover (4 screws). 8-11 FT5535/4527/4522...
  • Page 263 3. Remove the drive unit [B] (2 screws, 2 connectors). 4. Remove the separation roller gear [C]. 5. Remove the paper feed clutch [D] (1 connector). NOTE: When reinstalling the clutch, make sure that the clutch stopper groove engages the stopper bracket. FT5535/4527/4522 8-12...
  • Page 264 • When removing the paper feed roller gear, remove the rubber foot [D]. • Remove the joint bracket. After reinstalling the paper tray, perform the side-to side-registration adjustment (see Removal and Adjustment in the manual for the copier). 8-13 FT5535/4527/4522...
  • Page 265 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). FT5535/4527/4522 8-14...
  • Page 266 3. Remove the drive unit [A] (2 screws, 2 connectors). 4. Remove the vertical transport unit [B] (2 screws). 5. Remove the vertical transport guide [C] (4 screws). 6. Remove the sponge [D]. 7. Remove the relay sensors [E] (1 connector each). 8-15 FT5535/4527/4522...
  • Page 267 SECTION 9 PS270 PAPER TRAY UNIT (Machine Code: A553)
  • Page 268 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 FT5535/4527/4522...
  • Page 269 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 FT5535/4527/4522...
  • Page 270 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) FT5535/4527/4522...
  • Page 271 1. Right Support Bracket............. 1 2. Left Support Bracket ............... 1 3. Joint Bracket ................1 4. Shoulder Screw ..............1 5. Screw - M4 x 8................ 4 6. New Equipment Condition Report .......... 1 7. Installation Procedure ............1 FT5535/4527/4522...
  • Page 272 Proper reinstallation of the shipping retainers is required in order to avoid any transport damage. 1. Remove the strips of tape. 2. Remove the bottom plate stopper [A]. FT5535/4527/4522...
  • Page 273 11. Enter the proper paper size for each paper tray by following the instructions in the copier’s manual. 12. Attach the appropriate tray decals [K] which are included in the accessory box of the main copier. 13. Check the machine’s operation and copy quality. FT5535/4527/4522...
  • Page 274 5. Install the heater bracket [F] (2 screws). 6. Connect the heater harnesses. 7. Install the clamper [G] and clamp the heater harnesses. NOTE: After replacing the paper tray, perform the side-to-side registration adjustment (see the Removal and Adjustment section of the manual for the copier). FT5535/4527/4522...
  • Page 275 (10 s) 1st feed station 2nd feed station 3rd feed station Repeat Two paper feed tray type Repeat Three paper feed tray type Free Run Mode 2 The paper feed operation can be checked for the selected paper feed station. FT5535/4527/4522...

  • Page 276: Test Points

    4.2 TEST POINTS NUMBER FUNCTION TP101 + 5V TP102 + 24V TP103 TP104 TXD (Transmit signal) TP105 RXD (Receive signal) TP106 FT5535/4527/4522...
  • Page 277 Right Rear Cover [D]: 1. Remove the rear cover [A]. 2. Remove the right rear cover (2 screws). Left Cover [E]: 1. Remove the rear cover [A]. 2. Remove the front lower cover [B]. 3. Remove the left cover (4 screws). FT5535/4527/4522 9-10...
  • Page 278 4. Remove the spring [C]. 5. Remove the main motor [D] (4 screws, 1 clip, 1 gear). NOTE: When reinstalling the main motor assembly, make sure that the relay clutch stopper groove engages with the stopper [E] on the main motor bracket. 9-11 FT5535/4527/4522...
  • Page 279 2. Remove the link bracket [C] (2 screws). 3. Remove the main motor bracket assemlby (see Main Motor Replacement). 4. Remove the relay clutch [F] (1 connector). NOTE: When you reinstall a clutch, make sure that the clutch stopper groove engages the clutch stopper. FT5535/4527/4522 9-12...
  • Page 280 [b] and B size paper [c]. When paper jam and non-feed errors occur, change the feed roller position. • After reinstalling the paper tray, perform the side-to side-registration adjustment (see Removal and Adjustment in the manual for the copier). 9-13 FT5535/4527/4522...
  • Page 281 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. Remove the relay sensors [C] (1 connector each). FT5535/4527/4522 9-14...
  • Page 282 SECTION 10 ST26 20-BIN SORTER STAPLER (Machine Code: A554)
  • Page 283 " 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" 10-1 FT5535/4527/4522...
  • Page 284 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) FT5535/4527/4522 10-2...
  • Page 285 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 10-3 FT5535/4527/4522...
  • Page 286 22. Front Bin 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 FT5535/4527/4522 10-4...
  • Page 287 (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. 10-5 FT5535/4527/4522...
  • Page 288 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. FT5535/4527/4522 10-6...

  • Page 289: Accessory Check

    3. Staple Position Decal............1 4. Stepped Screw ..............1 5. Philips Truss Head Screw - M4 x 6 ........1 6. Philips Pan Head Screw - M4 x 14 ........4 7. New Equipment Condition Report (–17 machines only) ............1 8. Installation Procedure ............1 10-7 FT5535/4527/4522...
  • Page 290 Never hold the guide plate [B] when unpacking the sorter stapler. If you hold the guide plate, it might be damaged and this will cause paper jams. • Avoid catching the guide plate [B] on anything when installing the sorter stapler. FT5535/4527/4522 10-8...
  • Page 291 Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape and the shipping retainers [A]. 2. Open the front door [B] and remove the strips of tape from the staple unit and close the front door. 10-9 FT5535/4527/4522...
  • Page 292 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. FT5535/4527/4522 10-10...
  • Page 293 [J]. Finally, insert the lower stud [K] into the lower hinge hole [L]. 10. Remount the junction gate [F] (1 snap ring). 11. Connect the link lever [M] to the sorter stapler using the stepped screw [N], then close the sorter stapler. 10-11 FT5535/4527/4522...
  • Page 294 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. Mount the proof tray [C] (1 screw) as shown. FT5535/4527/4522 10-12...
  • Page 295 20. Turn on the copier main switch and test the operation of the sorter stapler. NOTE: The stapler will not be stapling for the first 10 or so copies until the first staple comes to the proper position from the cartridge. 10-13 FT5535/4527/4522...
  • Page 296 Grip motor • Stapler motor • Jogger motor (for A4 sideways) #1 and #2 are repeated together alternately. LED AND VARIABLE RESISTOR LED No. VR No. Function Adjusts bin sensor sensitivity TEST POINTS Number Function TP100 TP101 +24V TP102 FT5535/4527/4522 10-14...
  • Page 297 STAPLER REMOVAL 1. Open the front door [A] of the sorter stapler and swing the staple unit [B] up. 2. Remove the staple unit cover [C] (1 screw). 3. Remove the stapler [D] (1 screw and 1 connector). 10-15 FT5535/4527/4522...
  • Page 298 2. Swing out the sorter stapler and disconnect the link lever [B] (1 stepped screw). 3. Remove the front cover [C] (remove 2 screws and loosen 2 screws). 4. Remove the grip assembly [D] (2 screws and 1 connector). FT5535/4527/4522 10-16...
  • Page 299 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 FT5535/4527/4522...
  • Page 300 (3) Push the left side of the bin forward and pull that side up. (4) As you pull the left side up, the right wheel will leave its track. (5) When the left wheel reaches the slot [D], pull the bin out. FT5535/4527/4522 10-18...
  • Page 301 (3) Pass the left wheel [C] through the slot [D]. At the same time, pass the right wheel [E] just below the stapler opening. (4) Set the left wheel into the left track, then push the right wheel into the right track. 10-19 FT5535/4527/4522...
  • Page 302 Front Cover [B] (loosen 2 screws and remove 2 screws) • Rear Cover [C] (4 screws) 3. Turn the bin lift drive belt so that the bin lift gear/pulley component rotates counterclockwise. Continue this until the rear bin lift wire becomes loose enough to remove the wire. FT5535/4527/4522 10-20...
  • Page 303 5. Swing the bin shaft cover [B] as shown (2 screws and 1 connector). 6. Remove the bin support block stopper [C] as shown. 7. Remove the wire pulley [D] (1 E-ring). NOTE: Be careful not to lose the pin [E]. 8. Remove the bin lift wire [F]. 10-21 FT5535/4527/4522...
  • Page 304 11. Remove the bin lift shaft cover [B] (2 screws). 12. Remove the timing sensor bracket [C] (1 screw). 13. Remove the bin drive bracket [D] (2 screws with spring washer, 1 connector, and 3 wire saddles). 14. Remove the bushing [E]. FT5535/4527/4522 10-22...
  • Page 305 15. Remove the bin lift block stopper [A] as shown. 16. Remove the wire pulley/gear [B] (2 E-rings). NOTE: Be careful not to lose the pin [C]. 17. Remove the bin lift wire [D]. 10-23 FT5535/4527/4522...
  • Page 306 [P] in the slot in the bin lift shaft [Q]. 6. Reassemble the sorter stapler. NOTE: When installing the bin drive bracket, make sure that the bin lift wires are wound from the inner side to the outer side of the pulleys as shown. FT5535/4527/4522 10-24...
  • Page 307 [B] (1 screw). 4. Remove the grounding screw [C] and disconnect the main harness [D] (5 connectors and 3 harness clamps). 5. Remove the timing belt [E] from the pulley [F]. 6. Remove the vertical transport unit [G] (8 screws). 10-25 FT5535/4527/4522...
  • Page 308 2. Disconnect the main control board connectors and fiber cable. 3. Replace the main control board [B] and connect the connectors. 4. Turn on the copier main switch. 5. Adjust the bin sensor (see the next page). 6. Turn off the main switch. FT5535/4527/4522 10-26...
  • Page 309 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 FT5535/4527/4522...

  • Page 310: Belt Tension Adjustment

    (Roller Drive Motor) ........Proof Tray Rear Cover Timing Belt [B] (Grip Motor) ..........Proof Tray Front Cover 2. Adjust the timing belt tension as follows: Timing Belt Bending Tension 4 mm (0.16") 150±50 g 4 mm (0.16") 200±50 g FT5535/4527/4522 10-28...
  • Page 311 ≥ 4.0 V High) set of copies at the stapling position. Shorted The Sorter Jam The Sorter Jam (stays indicator starts blinking. indicator starts blinking ≤ 1.0 V Low) when copies are made 140-5 in sort/stack or staple mode. 10-29 FT5535/4527/4522...
  • Page 312 Bin Exit (S9) Open The Sorter Jam (stays – indicator starts blinking ≥ 4.0 V High) when copies are made in sort/stack or staple 150-4 Shorted The Sorter Jam mode. (stays indicator starts blinking. ≤ 1.0 V Low) FT5535/4527/4522 10-30...
  • Page 313 The Sorter Jam The Sorter Jam indicator starts blinking. indicator starts blinking Timing (stays ≥ 4.0 V (S11) High) or " SC code (720) " is 150-11 displayed when copies Shorted are made. (stays ≤ 1.0 V Low) 10-31 FT5535/4527/4522...
  • Page 314 FUSES Component Condition Symptom (Symbol) Open The Sorter Jam indicator starts blinking when copies are FU100 made in staple mode. (Main Control After the sorter stapler or front door is opened/closed, Board) "SC code (724)" will be displayed. FT5535/4527/4522 10-32...
  • Page 315 SECTION 11 ST10 10-BIN SORTER STAPLER (Machine Code: A555)
  • Page 316 / 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 11-1 FT5535/4527/4522...
  • Page 317 Average: less than 33 W Average for Sorting: less than 25 W Average for Stapling: less than 33 W Weight: 12.4 kg (27.4 lb) Dimensions (W x D x H): 381 x 548 x 443 mm (15.0" x 21.6" x 17.5") FT5535/4527/4522 11-2...
  • Page 318 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 FT5535/4527/4522...
  • Page 319 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 FT5535/4527/4522 11-4...

  • Page 320: Ft5535/4527/4522

    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 11-5 FT5535/4527/4522...

  • Page 321: Ft5535/4527/4522

    2. Staple Position Decal..........1 3. Chain................1 4. Cap Remover............1 5. Philips Pan Head Screw 4 x 8 ......... 1 6. Philips Pan Head Screw 4 x 14 ....... 4 7. New Equipment Condition Report ......1 8. Installation Procedure ..........1 FT5535/4527/4522 11-6...

  • Page 322: Ft5535/4527/4522

    Do not lift the sorter stapler by holding the entrance guide [A]. Otherwise, the resulting damage may cause paper jams to occur at the entrance. 1. Remove the strips of tape. 2. Remove the cardboard pieces [B] and the foam blocks [C]. 11-7 FT5535/4527/4522...

  • Page 323: Ft5535/4527/4522

    [D]. Then tighten four M4 x 14 screws. For A157, A159, A160, A161, and A162 copiers: First, remove the screw [E], and fit the hooks [B] on the sorter stapler mounting frame [C] into the openings [D]. Then tighten four M4 x 14 screws. FT5535/4527/4522 11-8...

  • Page 324: Ft5535/4527/4522

    7. Remove the Plug [P] from the rear of the copier. 8. Connect the cable [D] and the optic cable [E]. 9. Install the chain [F] as shown. 10. Attach the misfeed removal decal [G] and the staple position decal [H] as shown above. 11-9 FT5535/4527/4522...

  • Page 325: Ft5535/4527/4522

    14. Turn on the main switch, and test the operation of the sorter stapler. NOTE: The stapler will not be stapling for the first 5 or so copies after installation until the first staple comes to the proper position from the cartridge. FT5535/4527/4522 11-10...

  • Page 326: Ft5535/4527/4522

    - Staple Free Run Mode - This mode performs the jogger plate, grip assembly, and staple movements for each bin. - System Free Run Mode - This mode performs both sorter free run and staple free run modes. 11-11 FT5535/4527/4522...

  • Page 327: Ft5535/4527/4522

    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) FT5535/4527/4522 11-12...

  • Page 328: Ft5535/4527/4522

    4. Top Cover [D] (2 screws) 5.2 STAPLE UNIT REMOVAL 1. Remove the front cover (see Exterior Cover Removal). 2. Swing up the staple unit [A]. 3. Remove the staple unit (1 connector, 1 ground wire, 1 clip). 11-13 FT5535/4527/4522...

  • Page 329: Ft5535/4527/4522

    3. Remove the holder bracket [B] (1 screw). 4. Remove the spring [C] and remove the slider [D]. 5. Remove the grip arm unit [E] (1 screw, 1 clip). 6. Remove the grip arm plate [F] (2 screws). 7. Replace the grip arms [G]. FT5535/4527/4522 11-14...

  • Page 330: Ft5535/4527/4522

    9. Remove the helical wheels [K]. 10. Remove the bins [L]. NOTE: When putting back the helical wheels at both the front and rear of the machine, the parts labeled A should be pointing directly away from the machine. 11-15 FT5535/4527/4522...

  • Page 331: Ft5535/4527/4522

    3. Remove the entrance guide [C] (4 screws). 4. Remove the transport motor unit [D]. 5. Remove the collar [E]. 6. Remove the transport roller [F] (2 bushings, 1 gear). 7. Remove the transport motor cover [G]. 8. Remove the transport motor [H] (3 screws). FT5535/4527/4522 11-16...

  • Page 332: Ft5535/4527/4522

    1. Turn on the main switch. 2. Remove any copies from the bins. 3. Set switch 5 of DIP SW 100 on the sorter main board to the ON position. 4. Turn VR 100 until LED 100 goes off. 11-17 FT5535/4527/4522...
  • Page 333 SECTION 12 CS220 20-BIN SORTER (MINI - α) (Machine Code: A556)

  • Page 334: Ft5535/4527/4522

    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) 12-1 FT5535/4527/4522...

  • Page 335: Ft5535/4527/4522

    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 FT5535/4527/4522 12-2...

  • Page 336: Ft5535/4527/4522

    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 FT5535/4527/4522...

  • Page 337: Ft5535/4527/4522

    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 FT5535/4527/4522 12-4...

  • Page 338: Ft5535/4527/4522

    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. Knob Screw ..................2 12-5 FT5535/4527/4522...

  • Page 339: Ft5535/4527/4522

    CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape and the shipping retainer [A]. 2. Attach the entrance guide mylar [B] to the entrance guide plate [C]. FT5535/4527/4522 12-6...

  • Page 340: Ft5535/4527/4522

    7. Remount the sorter front cover [B] (2 screws) and the rear cover [C] (4 screws) and close the sorter top cover [A]. ⇒ 8. Remove the Plug [P] from the rear of the copier. 9. Connect the connector [H] to the socket [I] on the rear cover of the copier. 12-7 FT5535/4527/4522...

  • Page 341: Ft5535/4527/4522

    (3) The above procedure must be finished within 20 seconds. 11. Press the following sequence of keys to change the SP6-101 value to "2". → → → → → → → 12. Turn the main switch off and on. 13. Check the sorter’s operation. FT5535/4527/4522 12-8...

  • Page 342: Ft5535/4527/4522

    4. Swing the guide plate [A] up, then remove it carefully from the snaps on both sides by pulling it up. 5. Remove the inner cover [B] (4 screws). 6. Unhook the front [C] and rear [D] pressure springs. 12-9 FT5535/4527/4522...

  • Page 343: Ft5535/4527/4522

    14. Replace the exit roller and rubber belt, then reassemble the machine. NOTE: a) When reinstalling the wheel sensor assembly, be sure that the sensor does not touch the wheel. b) When remounting the wheel drive motor, adjust the timing belt tension. (See Timing Belt Tension Adjustment.) FT5535/4527/4522 12-10...

  • Page 344: Ft5535/4527/4522

    4. Swing up the guide plate [A]. 5. Remove the inner cover [B] (4 screws). 6. Replace the paper sensor [C] (1 screw and 1 connector) and reassemble the machine. CAUTION To avoid damaging the sensor, do not over-tighten the sensor mounting screw. 12-11 FT5535/4527/4522...

  • Page 345: Ft5535/4527/4522

    2. Loosen the two mounting screws [A] of the wheel drive motor [B]. 3. Press the timing belt [C] with a tension gauge [D] as shown in the diagram and adjust the tension by repositioning the wheel drive motor. FT5535/4527/4522 12-12...
  • Page 346 SECTION 13 CS130 10-BIN SORTER (MICRO - α) (Machine Code: A557)

  • Page 347: Ft5535/4527/4522

    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) 13-1 FT5535/4527/4522...

  • Page 348: Ft5535/4527/4522

    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 FT5535/4527/4522 13-2...

  • Page 349: Ft5535/4527/4522

    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. 13-3 FT5535/4527/4522...

  • Page 350: Ft5535/4527/4522

    2. Sorter Holder Bracket ..........1 3. Tapping Screw - M4 x 6 ..........3 4. Tapping Screw - M4 x 8 ..........2 5. Snap Ring ..............1 6. Installation Procedure ............ 1 7. New Equipment Condition Report ......... 1 FT5535/4527/4522 13-4...

  • Page 351: Ft5535/4527/4522

    Hold both sides of the sorter as shown by [B]. This is to prevent damage to the anti-static brush [C]. CAUTION Unplug the copier power cord before starting the following procedure. 1. Remove the strips of tape [D] and styrofoam blocks [E]. 2. Remove the copy tray [F]. 13-5 FT5535/4527/4522...

  • Page 352: Ft5535/4527/4522

    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. 7. Mount the magnetic catch [D] on the exit cover (2 self-tapping screws). FT5535/4527/4522 13-6...

  • Page 353: Ft5535/4527/4522

    (3) The above procedure must be finished within 20 seconds. 13. Press the following sequence of keys to change the "SP6-101" value to "1". → → → → → → → 14. Turn the main switch off and on. 15. Check the sorter’s operation. 13-7 FT5535/4527/4522...

  • Page 354: Ft5535/4527/4522

    1. If the bins are not at the home position, turn on the main switch of the copier to move the bins to the home position. 2. Secure the bins with strips of tape as shown in the illustration. 3. Remove the sorter from the copier. (See the Installation Procedure.) FT5535/4527/4522 13-8...

  • Page 355: Ft5535/4527/4522

    NOTE: Be careful not to damage the bin home position switch actuator [J] when reassembling. 8. Remove the transfer spacer [K], wheel [L], pin [M], and bushing [N] on both sides of the shaft. 9. Slide the wheel shaft towards the front and replace the roller drive belt. 13-9 FT5535/4527/4522...

  • Page 356: Ft5535/4527/4522

    3. Apply Grease 501 to the grooves of the bin guides. NOTE: There are three types of bins (types A, B, and C in the above diagram). Therefore, when installing the bins, be sure that they are installed in the correct order. FT5535/4527/4522 13-10...
  • Page 357 APPENDIX...

  • Page 358: Ft5535/4527/4522

    Table 11 Detect Supply Mode Table 12 Table 14 SP2-222: Supply Ratio 15% = default Toner TD Sensor Supply Table 12 SP2-208-002: Supply Ratio 15% = default Supply Mode Fixed Supply Mode Table 13 SP2-208-003: Supply Ratio 4% = default FT5535/4527/4522...

  • Page 359: Ft5535/4527/4522

    200 x 4.08 x (AR - 0.85) Lighter -80V T < 12.4 -580.0 -669.0 -808.0 Light 200 x 4.08 x (AR - 0.95) Lightest -120V SP2-001: Drum Charge Adjustment NOTE: AR(ADS Ratio) = V (original) / V (pattern) Range: 0(-480V) ~ 32(+480V) [Default = 16(±0V)] FT5535/4527/4522...

  • Page 360: Ft5535/4527/4522

    Amount of supplied toner for the specific time [constant] 0.126 ~ 0.160 --4 x 0.0196 0.161 ~ 0.205 --6 x 0.0196 0.183 (mg/ms) for A153, A155, A156 copiers 0.206 ~ 0.500 --8 x 0.0196 0.133 (mg/ms) for A157, A159, A160 copiers FT5535/4527/4522...

  • Page 361: Ft5535/4527/4522

    APPENDIX AUTO PROCESS CONTROL TIMING CHART (Every time after 1000 copies) FT5535/4527/4522...
  • Page 362 TECHNICAL SERVICE BULLETINS...
  • Page 363 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535 - 001 06/16/95 APPLICABLE MODEL: FT4027/4527/5035/5535 SUBJECT: FIELD SERVICE MANUAL - INSERT GENERAL: The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin package contains 2 sets of replacement pages. PAGES: ⇒...
  • Page 364 Cam Shape REFERENCE OLD PART NEW PART DESCRIPTION PAGE ITEM FT4527 FT5535 AB017372 AB017388 Blade Cam UNITS AFFECTED: All FT4027/4527/5035/5535 copiers manufactured after Serial Number A3635020001, A3715020001, A3625020001 and A3695020001 respectively will have the new style Blade Cam installed during production.
  • Page 365 PART NUMBER DESCRIPTION QUANTITY PAGE ITEM FT4527 FT5535 A1532117 Roller Terminal NOTE: The following changes apply to the FT5035/5535 only. 2. Delete the AC Drive Board - 115V (A1535546). 3. Change the description of the AC Drive Board - 230V (A1535545) to AC Drive Board - 115V.
  • Page 366 To obtain the latest version ROM at no charge, please complete and fax the attached form to Technica l Services or download a Hex file for local programming via the Ricoh Technical Services BBS (refer to Service News and Information No.147)
  • Page 367 Serial Number (s) All serial number information will be verified before shipment is made. NOTE: Old ROM’s must be returned within five (5) days to: Ricoh Corporation 146-148 Sound Beach Avenue Old Greenwich, CT 06870 PLEASE TYPE OR PRINT CLEARLY.
  • Page 368 TECHNICAL SERVICE BULLETIN BULLETIN NUMBER: 4027/4527/5035/5535 - 004 08/16/95 APPLICABLE MODEL: FT5035/5535 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The illustration found on page 42 of the FT5035/5535 Parts Catalog was also used (in error) on page 44. Please replace page 44 of your FT5035/5535 Parts Catalog with the corrected page provided. PAGES: Please insert the following page into your FT5035/5535 Parts Catalog: •...
  • Page 369 TECHNICAL SERVICE BULLETIN 2/7/96 BULLETIN NUMBER: 4027/4527/5035/5535 - 004 REISSUE APPLICABLE MODEL: FT5035/5535 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The illustration found on page 42 of the FT5035/5535 Parts Catalog was also used (in error) on page 44. Please replace page 44 of your FT5035/5535 Parts Catalog with the corrected page provided. PAGES: Please insert the following page into your FT5035/5535 Parts Catalog: •...
  • Page 370 08/16/95 APPLICABLE MODEL: FT4027/4527/5035/5535 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT5535/5035/4527/4027 Parts Catalogs. This information should be incorporated into all existing FT5535/5035/4527/4027 Parts Catalog documentation. • • UPDATE NO. 1 - PARTS CATALOG CORRECTION - Make the following corrections to your Parts...
  • Page 371 FT5535 FT4527 A1533554 A1533570 Spring Plate UNITS AFFECTED: All FT5535/5035/4527/4027 copiers manufactured after Serial Number A3695040001, A3625040001, A371505XXXX and A363505XXXX respectively will have the new style Spring Plate installed during production. Lower Fusing Guide • • UPDATE NO. 3 -...
  • Page 372 AA151177 Seal - 5 x 82 x 4 FT4527/4027 AA151177 Seal - 5 x 82 x 4 UNITS AFFECTED: All FT5535/5035/4527/4027 copiers manufactured after Serial Number A3695030001, A3625030001, A371504XXXX and A363504XXXX respectively will have the new Seal installed during production.
  • Page 373 The One-Way Clutch has been changed to a different type to reduce the friction between the Feed Roller Shaft and Needle Pins. The locations of the One-Way Clutch are shown below. NOTE: The FT5035 uses 3 One-Way Clutches and, due to the LCT, the FT5535 uses only 2 One-Way Clutches.
  • Page 374 • The expected occurrence ratio for the FT5535 is lower than that of the FT5035. This is because, generally speaking, a machine with an LCT (FT5535) uses the LCT more than the other feed trays in the machine.
  • Page 375 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 3 of 8 Clutch Replacement Procedure For the FT5035 1. Remove the by-pass feed table [A] (1 clip, 1 connector). 2. Remove Accessory Connectors from rear of machine. 3. Remove the rear cover. 4.
  • Page 376 Paper Feed Drive Roller and the Feed Roller Shaft Replacement Procedures. [ R ] [ P ] For the FT5535 1. Remove the by-pass feed table [ A ] (1 clip, 1 connector). 2. Remove accessory connectors from rear of machine.
  • Page 377 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 5 of 8 8. Remove the front cover. (2 hinge pins) 9. Remove the registration knob-A2 and middle knob-A3 (1 screw each). 10. Remove the right inner cover. [ J ] 11. Remove the LCT set block [ B ] (1 screw).
  • Page 378 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 6 of 8 Drive Belt Layout Clutch and Gear Layout The FT5535 does not The FT5535 does not have this part have this part Continued...
  • Page 379 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 7 of 8 FT5535 Upper Paper Feed Drive Roller Replacement Procedure (Front) Guide Plate 1. Remove the Guide Plate (2 screws) 2. Remove the E-ring from the front end of the Paper Feed Drive Roller (Rear) 3.
  • Page 380 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 8 of 8 FT5035/5535 Feed Roller Shaft Replacement Procedure. 1. Remove the Feed Roller (1 - Snap ring) 2. Remove the retaining ring. (The ring is shaped white plastic) 3. Remove the Feed Roller Shaft and remove the other retaining ring from the Feed Roller Shaft and fix it to the new Feed Roller Shaft.
  • Page 381 The One-Way Clutch has been changed to a different type to reduce the friction between the Feed Roll er Shaft and Needle Pins. The locations of the One-Way Clutch are shown below. NOTE: The FT5035 uses 3 One-Way Clutches and, due to the LCT, the FT5535 uses only 2 One-Way Clutches.
  • Page 382 • The expected occurrence ratio for the FT5535 is lower than that of the FT5035. This is because, generally speaking, a machine with an LCT (FT5535) uses the LCT more than the other feed trays in the machine.
  • Page 383 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 3 of 8 Clutch Replacement Procedure For the FT5035 1. Remove the by-pass feed table [A] (1 clip, 1 connector). 2. Remove Accessory Connectors from rear of machine. 3. Remove the rear cover. 4.
  • Page 384 Paper Feed Drive Roller and the Feed Roller Shaft Replacement Procedures. [ R ] [ P ] For the FT5535 1. Remove the by-pass feed table [ A ] (1 clip, 1 connector). 2. Remove accessory connectors from rear of machine.
  • Page 385 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 5 of 8 8. Remove the front cover. (2 hinge pins) 9. Remove the registration knob-A2 and middle knob-A3 (1 screw each). 10. Remove the right inner cover. [ J ] 11. Remove the LCT set block [ B ] (1 screw).
  • Page 386 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 6 of 8 Drive Belt Layout Clutch and Gear Layout The FT5535 does not The FT5535 does not have this part have this part Continued...
  • Page 387 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 7 of 8 FT5535 Upper Paper Feed Drive Roller Replacement Procedure (Front) Guide Plate 1. Remove the Guide Plate (2 screws) 2. Remove the E-ring from the front end of the Paper Feed Drive Roller (Rear) 3.
  • Page 388 Tech Service Bulletin No. 4027/4527/5035/5535 - 006 Page 8 of 8 FT5035/5535 Feed Roller Shaft Replacement Procedure. 1. Remove the Feed Roller (1 - Snap ring) 2. Remove the retaining ring. (The ring is shaped white plastic) 3. Remove the Feed Roller Shaft and remove the other retaining ring from the Feed Roller Shaft and fix it to the new Feed Roller Shaft.
  • Page 389 4027/4527/5035/5535/4022/4522 - 007 10/11/95 APPLICABLE MODEL: FT4027/4527/5035/5535/4022/4522 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT5535/5035/4527/4027/4522/4022 Parts Catalogs. This information should be incorporated into all existing FT5535/5035/4527/4027/4522/4022 Parts Catalog documentation. • • UPDATE NO. 1 -...
  • Page 390 M3 X 10 UNITS AFFECTED: All FT5535/5035 copiers manufactured after Serial Number A3695050001 and A3625050001 respectively and all FT4527/4027 copiers manufactured after Serial Number A371506XXXX and A363506XXXX respectively will have the new style Scanner Drive Shaft etc... installed during production.
  • Page 391 TONER HOPPER GEARS - Per field request, the following parts have been made available as service parts. Coupled Gear 15Z/22Z Gear 17Z Gear 26Z REFERENCE MODEL NEW PART DESCRIPTION QUANTITY FT5535/5035 FT4027/4527 FT4522/4022 NUMBER PAGE ITEM PAGE ITEM PAGE ITEM...

  • Page 392: Ft5535/4527/4522

    Page 4 of 4 • • UPDATE NO. 5 - PUSH SWITCH - The Part Number listed on page 71, item 5 is incorrect. Correct the Part Number in all three sections (FT5535/4527/4522) of the Parts Catalog. REFERENCE INCORRECT CORRECT...
  • Page 393 NOTE: The Fiber Connector Plug must be removed when a peripheral is installed (save for future use). Fiber Connector UNITS AFFECTED: Not available at time of publication. REFERENCE MODEL NEW PART DESCRIPTION FT5535/5035 FT4027/4527 FT4522/4022 NUMBER PAGE ITEM PAGE ITEM PAGE ITEM...
  • Page 394 Reform the Wiper Arm Spring as shown so that there is no end play PRODUCTION COUNTERMEASURE: The Wiper Arm Spring has been modified and is now available as a service part. NOTE: Add the Wiper Arm Spring to your Parts Catalog REFERENCE MODEL NEW PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE...
  • Page 395 ENERGY STAR MODIFICATION (DETAILS) GENERAL: From the August, 1995 production run, all FT5535 Series copiers have already met 1997 Energy Star specifications set by the Environmental Protection Agency (EPA - tier 2). Modifications to these ma chines effect the following three modes: Energy Saver Mode, Auto "OFF" Mode and Duplex Default Mode. Speci fic details are as follows: •...
  • Page 396 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 010 Page 2 of 6 • • AUTO "OFF" MODE When the Auto "OFF" timer expires, the machine cuts all power to the copier. The Auto "OFF" timer ca n be programmed with SP5-305. The power is re-supplied when the main switch is turned back on. The main switch for this copier has three positions.
  • Page 397 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 010 Page 3 of 6 Connector Layout Main SW Wire Color Connector Terminal No. Color White Yellow Blue Blue Black Yellow Blue Yellow White Orange White Relay Wire Color Connector Terminal l No. Color White Yellow Orange...
  • Page 398 Function Settings SP5-911 Copy mode selected when machine is turned on 1 : Duplex Copy Mode (Default) (FT5535, FT4527, FT4522 copiers) 2 : Single Side Copy Mode SP5-102 Auto energy saver time can be selected. 1 ~ 120 minutes (1 minute per step)
  • Page 399 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 010 Page 5 of 6 Continued...
  • Page 400 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 010 Page 6 of 6...
  • Page 401 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 011 1/26/95 APPLICABLE MODEL: FT4027/4527/5035/5535/4022/4522 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all 4027/4527/5035/5535/4022/4522 Parts Catalogs. T his information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 402 Main Board A1575101 A1575181 Main Board A1535104 A1535106 IC-4M x 16-120NS (ROM) A1535545 A1535550 AC Drive Board - 120V A1545309 A1565509 Duplex Rear Harness (FT5535) A1585309 A1565509 Duplex Rear Harness (FT4527/4522) A1535311 A1535511 Rear Lower Harness (FT5035) A1575311 A1575511 Rear Lower Harness - 2...
  • Page 403 NOTE: NATP found in the "T" column of the part chart (see page 2) indicates "Not Available at Time of Production" FT5035 - A3625070001 FT4027 - A363508XXXX FT4022 - A364508XXXX FT5535 - A3695070001 FT4527 - A371508XXXX FT4522 - A372508XXXX FT5035 - A3625080001 FT4027 - A363509XXXX...
  • Page 404 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP 03/20/96 BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 011REISSUE APPLICABLE MODEL: FT4027/4527/5035/5535/4022/4522 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all 4027/4527/5035/5535/4022/4522 Parts Catalogs. T his information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 405 Main Board A1575101 A1575181 Main Board A1535104 A1535106 IC-4M x 16-120NS (ROM) A1535545 A1535550 AC Drive Board - 120V A1545309 A1565509 Duplex Rear Harness (FT5535) A1585309 A1565509 Duplex Rear Harness (FT4527/4522) A1535311 A1535511 Rear Lower Harness (FT5035) A1575311 A1575511 Rear Lower Harness - 2...
  • Page 406 NOTE: NATP found in the "T" column of the part chart (see page 2) indicates "Not Available at Time of Production" FT5035 - A3625070001 FT4027 - A363508XXXX FT4022 - A364508XXXX FT5535 - A3695070001 FT4527 - A371508XXXX FT4522 - A372508XXXX FT5035 - A3625080001 FT4027 - A363509XXXX...
  • Page 407 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 012 2/7/96 APPLICABLE MODEL: FT4022/4522/4027/4527/5035/5535 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT4022/4522/4027/4527/5035/5535 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 408 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 012 Page 2 of 2 REFERENCE MODEL PART FT5535/5035 FT4027/4527 FT4522/4022 NUMBER DESCRIPTION QUANTITY PAGE ITEM PAGE ITEM PAGE ITEM A1344006 Fusing Exit Unit A1534005 Fusing Unit - 115V A1574005 Fusing Unit - 115V...
  • Page 409 CAUSE: 0 ~ 0.5mm Light is reflected from the 6th mirror bracket. SOLUTION: A Mirror Seal has been added to correct the problem. 0 ~ 0.5mm REFERENCE MODEL PART FT5535/5035 FT4027/4527 NUMBER DESCRIPTION PAGE ITEM PAGE ITEM 0 → 1...
  • Page 410 LEFT ORIGINAL SCALE - To prevent the left original scale from warping, a metal plate has been added to the new scale. The scale bracket, which was missing in the parts catalog, has also been changed. REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022...
  • Page 411 A1556112 Spacer - LCT * DENOTES NEW ITEM UNITS AFFECTED: All FT5535 copiers manufactured after Serial Number A3695090061 will have the Spacer installed durin g production. Serial Number information for the FT4527 was not available at time of publication. Continued...
  • Page 412 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 014 Page 3 of 3 • • UPDATE NO. 4 - TIMING BELT - The material of the Timing Belt has been changed to improve durability. REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE...
  • Page 413 Front and New Fusing Exit Guides Rear Fusing Exit Guides. The new Fusing Exit Guides are positioned as shown. A: 0 ~ 1 mm B: 0 ~ 0.5 mm REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM...
  • Page 414 Center NOTE: Align the edge of the cushion at the point where the stay is bent at a slight angle. REFERENCE MODEL FT5535/5035 FT4027/4527 FT4522/4022 PART DESCRIPTION QUANTITY NUMBER PAGE ITEM...
  • Page 415 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 Page 3 of 6 UNITS AFFECTED: All FT5535/4527 copiers manufactured after Serial Number A3695110001 and A371512XXXX respectively will have the new Cushion installed during production. Serial Number information for the FT4522 was not available at time of publication.
  • Page 416 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 Page 4 of 6 UNITS AFFECTED The Stripper Bracket & Fusing Exit Frame were cut into production with the following Serial Numbers: • FT5035/5535 - A362511XXXX / A3695100001 • FT4027/4527 - A3635920351 / A3715911752 •...
  • Page 417 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 Page 5 of 6 REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM PAGE ITEM 2 → 2 AA060602 AA060658 Spring - Pressure - 66n 2 → 2 AA060605 AA060659...
  • Page 418 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 Page 6 of 6 PARTS CATALOG - INSERT GENERAL: The Parts Catalog page(s) listed below must be inserted into all FT5035/5535/4027/4527/4022/74522 Parts Catalogs. Each bulletin package contains 1 set of insert pages. PAGES: ⇒...
  • Page 419 Front and Rear Fusing Exit Guides. The new Fusing Exit Guides are positioned as shown. A: 0 ~ 1 mm B: 0 ~ 0.5 mm REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE...
  • Page 420 Thermistor and the Bracket. This, in turn, will prevent an unnecessary SC544 indication. Old Type New Type Plastic Bracket Metal Bracket Thermistor Thermistor REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM PAGE ITEM 1 →...
  • Page 421 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 REISSUE Page 3 of 6 UNITS AFFECTED: All FT5535/4527 copiers manufactured after Serial Number A3695110001 and A371512XXXX respectively will have the new Cushion installed during production. Serial Number information for the FT4522 was not available at time of publication.
  • Page 422 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 REISSUE Page 4 of 6 UNITS AFFECTED The Stripper Bracket & Fusing Exit Frame were cut into production with the following Serial Numbers: • FT5035/5535 - A362511XXXX / A3695100001 • FT4027/4527 - A3635920351 / A3715911752 •...
  • Page 423 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 REISSUE Page 5 of 6 REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM PAGE ITEM 2 → 2 AA060602 AA060658 Spring - Pressure - 66n 2 → 2 AA060605 AA060659...
  • Page 424 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 015 REISSUE Page 6 of 6 PARTS CATALOG - INSERT GENERAL: The Parts Catalog page(s) listed below must be inserted into all FT5035/5535/4027/4527/4022/74522 Parts Catalogs. Each bulletin package contains 1 set of insert pages. PAGES: ⇒...
  • Page 425 This information should be incorporated into all existing Parts Catalog documentation. • • UPDATE NO. 1 - DUPLEX TRAY ASSEMBLY - A part number has been assigned for the Duplex Tray Assembly. Duplex Tray Assembly REFERENCE MODEL FT5535 FT4527/4522 PART NUMBER DESCRIPTION PAGE ITEM PAGE ITEM 0 →...
  • Page 426 • • UPDATE NO. 2 - PARTS CATALOG CORRECTIONS - Correct the part number as follows: 1. The part number for the Front Side Plate is incorrect. REFERENCE MODEL INCORRECT CORRECT FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE...
  • Page 427 TONER END SENSOR COVER - The Toner End Sensor Cover has been added to prevent damage to the sensor when the development unit is removed or installed. Toner Hopper Tapping Bind Screw Toner End Sensor Toner End Sensor Cover REFERENCE MODEL FT5535/5035 FT4027/4527/ PART NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE ITEM A1533227...
  • Page 428 0.3mm Duplex Guide Mylar Mylar The distance between the edge of the mylar and the center of the feed roller shaft is 16.2 ± 0.3 mm. REFERENCE MODEL FT5535 FT4527/4522 PART NUMBER DESCRIPTION PAGE ITEM PAGE ITEM 0 → 1...
  • Page 429 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 017 04/01/96 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: NON-ENERGY STAR COPIER MAIN BOARD GENERAL: The old style (pre-Energy Star) Main Boards are no longer available as service parts. However, the new style (Energy Star) Main Board can be used in older (non-Energy Star) machines as long as the old RO M is installed on the new Main Board.
  • Page 430 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 018 06/04/96 APPLICABLE MODEL: FT4022/4522/4027/4527/5035/5535 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT4022/4522/4027/4527/5035/5535 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 431 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 2 of 5 • • UPDATE NO. 2 - To prevent the transfer belt from being worn by the tapering part of the belt drive roller, the tapering part has been rounded off. This part has been rounded off Tapering Part Belt Drive Roller...
  • Page 432 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 3 of 5 Rear Scanner Stay Front Scanner Stay Main Switch Bracket Interlock Switch Bracket Toner Supply Stay Interlock Switch Left Grip Arm Right Bracket - Grip Plate Left bracket - Grip Plate Left Grip Arm Continued...
  • Page 433 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 4 of 5 Tray Unit Bracket ARDF Bracket Second Mylar Continued...
  • Page 434 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 5 of 5 REFERENCE MODEL FT5535/5035 FT4027/4527/ PART DESCRIPTION 4522/4022 NUMBER PAGE ITEM PAGE ITEM A1531850 Lens Cover 11026739 Connector - 12P A1531773 Rear Scanner Stay A1531772 Front Scanner Stay A1535809 Interlock Switch Arm...
  • Page 435 The plastic part is illustrated below. Charge Roller Terminal Charge Receptacle Rear Roller Rear Support Shaft Plastic REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM PAGE ITEM 1 →...
  • Page 436 To prevent the transfer belt from being worn by the tapering part of the belt drive roller, the tapering part has been rounded off. This part has been rounded off Tapering Part Belt Drive Roller REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER...
  • Page 437 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 3 of 5 Rear Scanner Stay Front Scanner Stay Main Switch Bracket Interlock Switch Bracket Toner Supply Stay Interlock Switch Left Grip Arm Right Bracket - Grip Plate Left bracket - Grip Plate Left Grip Arm Continued...
  • Page 438 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 4 of 5 Tray Unit Bracket ARDF Bracket Second Mylar Continued...
  • Page 439 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 018 Page 5 of 5 REFERENCE MODEL FT5535/5035 FT4027/4527/ PART DESCRIPTION 4522/4022 NUMBER PAGE ITEM PAGE ITEM A1531850 Lens Cover 11026739 Connector - 12P A1531773 Rear Scanner Stay A1531772 Front Scanner Stay A1535809 Interlock Switch Arm...
  • Page 440 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 40274527/5035/5535/4022/4522 - 019 07/25/96 APPLICABLE MODEL: FT4022/4522/4027/4527/5035/5535 SUBJECT: PARTS CATALOG UPDATES • • UPDATE NO. 1 - Part numbers have been assigned for both the Rubber Foot and Auto Response Sensor. This information should be incorporated into all existing FT4022/4522/4027/4527/5035/5535 Parts Catalog documentation.
  • Page 441 1. The LEDs on the Quenching Lamp are broken or OPEN. 2. Poor solder joints attaching the Quenching Lamp wiring harness. SOLUTION 1. Replace the Quenching Lamp (A1532090). 2. Re-solder the wires to the Quenching Lamp. UNITS AFFECTED: Any FT5535 Series copier exhibiting the above symptoms.
  • Page 442 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 021 09/04/96 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: OFFSET IMAGES SYMPTOM: Faint characters and/or images appear in non-image areas. CAUSE: Various problems associated with toner fusing. SOLUTION When an offset problem occurs, it is very important to correctly isolate the cause and utilize the p roper countermeasure to solve the problem.
  • Page 443 Tech Service Bulletin No. FT4027/4527/5035/5535/4022/4522 - 021 Page 2 of 4 Cold Offset (incomplete fusing) Offset (125mm pitch) only occurs in the morning when the machine is first turned on or when using thick paper. Action: • Check the environment temperature. In conditions under 10 ° C and 15% humidity, problems may occur when the machine is turned on at the beginning of the day.
  • Page 444 Tech Service Bulletin No. FT4027/4527/5035/5535/4022/4522 - 021 Page 3 of 4 Insufficient Pressure Roller Cleaning Offset Occurs irregularly. Large "clumps" of toner fall off the pressure roller cleaning roller onto the c opy paper. The toner can be wiped off by hand. This can occur over the whole paper surface and usually involve s large amounts of toner.
  • Page 445 • Was the total number of copies made while the machine was in use extremely high or low? • Is the toner a Ricoh product? • Is the hot roller a Ricoh product? • Is the pressure roller a Ricoh product? •...
  • Page 446 In addition to cleaning the charge roller, please check the cleaning blade. Even if no defective or deteriorated areas can be found on the blade, it may be necessary to replace it with a new one. UNITS AFFECTED: All FT5535 Series copiers exhibiting the above symptom.
  • Page 447 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 023 09/27/96 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT5035/5535/4027/4527/4022/4522 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 448 Page 2 of 2 • • UPDATE NO. 2 - STRIPPER STOPPER - The Stripper Stopper is available as a service part. Stripper Stopper Hot Roller Stripper REFERENCE MODEL PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE ITEM A1534114...
  • Page 449 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP 01/16/97 BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 023 REISSUE APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: PARTS CATALOG UPDATES GENERAL: The following Parts Updates are being issued for all FT5035/5535/4027/4527/4022/4522 Parts Catalogs. This information should be incorporated into all existing Parts Catalog documentation. •...
  • Page 450 Page 2 of 2 • • UPDATE NO. 2 - STRIPPER STOPPER - The Stripper Stopper is available as a service part. Stripper Stopper Hot Roller Stripper REFERENCE MODEL PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE ITEM A1534114...
  • Page 451 This information should be incorporated into all existing Parts Catalog documentation. • • UPDATE NO. 1 - PARTS CATALOG CORRECTION - Correct the part number for the Drum Unit is shown below. REFERENCE MODEL INCORRECT CORRECT FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM...
  • Page 452 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 024 Page 2 of 3 • • UPDATE NO. 2 - MAGNETIC CLUTCH - The Magnetic Clutch has been changed to prevent it from rusting. REFERENCE OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM 1 →...
  • Page 453 Page 3 of 3 • • UPDATE NO. 4 - PAPER SIZE DECAL - The Part Number for the Paper Size Decal was missing from the Parts Catalog. REFERENCE MODEL PART FT5535/5035 FT4027/4527 FT4522/4022 NUMBER DESCRIPTION QUANTITY PAGE ITEM PAGE ITEM...
  • Page 454 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 025 11/08/96 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: SOFTWARE MODIFICATION SYMPTOM 1: DEVELOPER LEAKAGE - The Main Motor, Charge Roller, Transfer Belt and Development Unit are continuously in the ON condition. This results in developer leakage from the Development Unit and ultimately leads to blank copies because of a shortage of developer.
  • Page 455 ORDERING PROCEDURE: This software may be downloaded from the Ricoh Technical Services BBS or by completing and faxing th e attached form. NOTE: For more information about the Ricoh Technical Services BBS, order the Guide To Operation (BBS00001) through normal NSPC channels or download document #1001, #1002 &...
  • Page 456 Each serial number given will represent a request for one ROM (A1535109) Serial Number (s) All serial number information will be verified before shipment is made. NOTE: Old ROM’s must be returned within five (5) days to: Ricoh Corporation 2001 West Main Street, Suite 255 Stamford, CT 06902 UNITS AFFECTED:...
  • Page 457 Noise is generated by the Hot Roller Strippers. Hot Roller Stripper CAUSE: The angle of the Hot Roller Strippers. SOLUTION The angle of the Hot Roller Stripper has been changed as shown. REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM...
  • Page 458 The R (Arc) has been increased as shown. NOTE: If the hooks of the guide plate break off, the guide plate moves up a little and sometimes causes a paper misfeed. REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER...
  • Page 459 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 027 Page 2 of 2 • • UPDATE NO. 2 - A part number has been assigned for the IC-2 on the Main Board. REFERENCE MODEL PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE ITEM 1 →...
  • Page 460 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 028 11/18/96 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: BLACK LINES ON COPIES AND/OR HIGH-PITCHED NOISE SYMPTOM: Black lines on copies and/or a high pitched noise coming from the drum cavity. CAUSE: The Development Entrance Seal (AA152333) is in contact with the drum resulting in scratches on the O P C surface.
  • Page 461 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 028 Page 2 of 4 FIELD COUNTERMEASURE: 1. Replace the seals (AA142333 & AA152334) with new ones. Be sure to first clean the areas where the seals will be attached. Align the edge of the seal with the edge of the bracket. AA152333 AA152334 Align the edge of the seal with the edge of the bracket.
  • Page 462 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 028 Page 3 of 4 2. Turn the Drum Unit over and attach the Mylar (A1533591) in the position shown. Front Rear A : 0 ~ 0.5 mm B : 0 ~ 2 mm Upper Guide Make sure that the 2-sided adhesive tape does not stick out beyond the end of the upper guide and that the mylar is flat.
  • Page 463 Transfer Entrance Guide and the Entrance Guide Plate has been modified to raise the angle at which t he paper enters. Mylar A1533591 A1533901 A1533899 Entrance Guide Plate Entrance Guide Plate REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM...
  • Page 464 NOTE: Only page 1 and 2 of 4 have been reissued. Retain the original page 3 and 4 of 4 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP 02/28/97 BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 028 REISSUE APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: BLACK LINES ON COPIES AND/OR HIGH-PITCHED NOISE SYMPTOM: Black lines on copies and/or a high pitched noise coming from the drum cavity.
  • Page 465 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 028 REISSUE Page 2 of 4 FIELD COUNTERMEASURE: 1. Replace the seals (AA152333 & AA152334) with new ones. Be sure to first clean the areas where the seals will be attached. Align the edge of the seal with the edge of the bracket. AA152333 AA152334 Align the edge of the seal with the edge of the bracket.
  • Page 466 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 028 Page 3 of 4 2. Turn the Drum Unit over and attach the Mylar (A1533591) in the position shown. Front Rear A : 0 ~ 0.5 mm B : 0 ~ 2 mm Upper Guide Make sure that the 2-sided adhesive tape does not stick out beyond the end of the upper guide and that the mylar is flat.
  • Page 467 Transfer Entrance Guide and the Entrance Guide Plate has been modified to raise the angle at which t he paper enters. Mylar A1533591 A1533901 A1533899 Entrance Guide Plate Entrance Guide Plate REFERENCE MODEL FT5535/5035 FT4027/4527/ PART PART DESCRIPTION 4522/4022 NUMBER NUMBER PAGE ITEM...
  • Page 468 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 029 01/16/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: DIRTY BACKGROUND SYMPTOM: Dirty background associated with machines that are located in dusty environments. CAUSE: 1. Concerning low copy volume machines: The lamp voltage correction/compensation by the process control every 1K copies cannot catch up with the lamp voltage level necessary to eliminate the dirty background.
  • Page 469 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 029 Page 2 of 2 Filter Installation Procedure: Upper Cover Optics Filter (Left) Optics Filter (Right) 1. Remove the upper cover 2. Install both the left and right filters so that the holes on the filters are aligned with the holes on the optics frame.
  • Page 470 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 029REISSUE 04/14/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: DIRTY BACKGROUND SYMPTOM: Dirty background associated with machines that are located in dusty environments. CAUSE: 1. Concerning low copy volume machines: The lamp voltage correction/compensation by the process control every 1K copies cannot catch up with the lamp voltage level necessary to eliminate the dirty background.
  • Page 471 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 029 REISSUE Page 2 of 2 Filter Installation Procedure: Upper Cover Optics Filter (Left) Optics Filter (Right) 1. Remove the upper cover 2. Install both the left and right filters so that the holes on the filters are aligned with the holes on the optics frame.
  • Page 472 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 030 01/16/97 APPLICABLE MODEL: FT4022/4522/4027/4527/5035/5535 SUBJECT: UPPER FUSING GUIDE SCREWS SYMPTOM: A groove is worn into the surface of the Hot Roller resulting in lines on copies and possible damage to the Transfer Belt.
  • Page 473 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 031 02/28/97 APPLICABLE MODEL: FT5035/5535 SUBJECT: TRAY SIDE FENCES GENERAL: The material of the Side Fences has been changed to increase durability. This information should be incorporated into all existing FT5035/5535/4027/4527/4022/4522 Parts Catalog documentation. REFERENCE OLD PART NO.
  • Page 474 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 032 02/28/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: SC E501 through E506 SYMPTOM: SC E501 through E506 CAUSE: Paper falls to the rear side of the Paper Tray and blocks the lift mechanism. SOLUTION: The Paper Talon has been added on the Paper Tray to prevent paper from blocking the lift mechanism.
  • Page 475 Sensor Board from being deformed. The part numbers of the By-pass Feed Cover and the Front Fence Rack have not been changed. Also, the Cushion - 10 x 30 x 5 (AA151998) has been removed with this modification. REFERENCE MODEL OLD PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM...
  • Page 476 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 033 Page 2 of 2 • • UPDATE NO. 2 - The Platen Cover Bracket (A1531380) and two screws (04140142B) are not included in the Platen Cover Ass’y (A1531369). Please make the correction of the dotted line area in the Parts Catalog (page 10) as shown below.
  • Page 477 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 034 05/06/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: PARTS CATALOG CORRECTION GENERAL: Correct the Part Descriptions as shown below. This information should be incorporated into all exist ing FT5035/5535/4027/4527/4022/4522 Parts Catalog documentation. FT5035/5535 REFERENCE PART NO.
  • Page 478 CLEANING ROLLER & BUSHINGS - Due to part standardization, the following part have been changed. Also, the material of the bushing has been changed to increase reliability in high temperatures. REFERENCE MODEL FT5535/5035 FT4027/4527 FT4522/4022 PART PART DESCRIPTION QUANTITY INT...
  • Page 479 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 036 06/13/97 APPLICABLE MODEL: FT4027/4527/5035/5535/4022/4522 SUBJECT: PADDLE ROLLER BUSHINGS WEARING OUT SYMPTOM: Developer leakage from the Paddle Roller Bushings in the Development Unit. CAUSE: The V-ring on the Paddle Roller is out of position. Paddle Roller V-ring V-ring...
  • Page 480 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 036 Page 2 of 3 DO NOT LOOSEN Entrance Seal Ass’y [C] (A1533075) THESE SCREW Seal [B] (AA150231) Screw [D] Seal [A] (AA150382) Side Bracket [E] Screw [F] 6. Separate the Upper and Lower Unit 3 screws [G] & 1 screw [H]. 7.
  • Page 481 Paddle Roller Assembly - Part Numbers have been assigned for the following components in the Development Unit. This Information should be incorporated in all existing Parts Catalog documentation. REFERENCE MODEL NEW PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE...
  • Page 482 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 037 06/13/97 APPLICABLE MODEL: FT4027/4527/5035/5535/4022/4522 SUBJECT: DRUM FILMING WITH TONER SYMPTOM: The OPC Drum becomes covered with a black substance, most likely toner, after 8K to 20K copies. The surface of the Drum looks as if is being coated by toner in a width equal to that of the paper or th e Development Roller.
  • Page 483 Has Been Eliminated 5535 - Page 50 5535 - Page 54 4522 - Page 48 4527 - Page 52 4527 - Page 48 4527 - Page 52 REFERENCE MODEL FT5535/5035 FT4027/4527 FT4522/4022 PART PART DESCRIPTION QUANTITY NUMBER NUMBER PAGE ITEM...
  • Page 484 SHIELDING MYLAR and BOTTLE UNIT HOLDER - The part numbers for the Shielding Mylar and the Bottle Unit Holder have been assigned. Index 36: Bottle Unit Holder A153 - 3272 Index 23: Shielding Mylar AA15 - 0367 REFERENCE MODEL PART FT5535/5035 FT4027/4527/ NUMBER DESCRIPTION 4522/4022 PAGE ITEM PAGE ITEM AA150367...
  • Page 485 A1344654 A2044651 Bottom Pressure Plate UNITS AFFECTED: All FT5535/4027/4522 copiers manufactured after Serial Number A3696110001, A371611XXXX and A372611XXXX respectively will have the new style Bottom Pressure Plate installed during production. The thickness of this plate has been changed • •...
  • Page 486 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 039 Page 3 of 4 • • UPDATE NO. 4 - The part numbers for the following parts have been assigned as per field request. REFERENCE MODEL NEW PART FT5535/5035 FT4027/4527 FT4522/4022 NUMBER DESCRIPTION QUANTITY PAGE ITEM PAGE...
  • Page 487 Tech Service Bulletin No. 4027/4527/5035/5535/4022/4522 - 039 Page 4 of 4 ( Reference Table ) Operation Panel Ass’y Print Circuit Board AG011314 A1595460 AG011315 A1605461 FT4527/4027 AG011316 A1595465 AG011317 A1605466 AG011321 A1595460 AG011322 A1605461 AG011323 A1595460 AG011325 A1605461 AG011324 A1595465 FT4522/4022 AG011326 A1605466...
  • Page 488 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 040 08/29/97 APPLICABLE MODEL: FT4027/4527/4022/4522 SUBJECT: PARTS CATALOG CORRECTION GENERAL: The Toner Hopper Ass’y (A1533200) is listed, in error, on page 35 of the FT4027/4527/4022/4522 Parts Catalog. This item is already listed, correctly, on page 37 (item #3). This information should be i ncorporated into all existing FT4027/4527/4022/4522 Parts Catalog documentation.
  • Page 489 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 041 08/29/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: OPTICAL FILTER GENERAL: The Shield Glass has been eliminated to facilitate assembly. Also, the film on the Optical Filter h as been extended to cover the entire window of the Optical Filter and the step height of the shield Glass Gu ide has been reduced to match the thickness of Optical Filter.
  • Page 490 Tech Service Bulletin No. 5035/5535/4027/4527/4022/4522 -041 page 2 of 2 UNITS AFFECTED: All FT5035/5535/4027/4527/4022/4522 copier manufactured after Serial Number A3627020001/A3697010001/A3637810462/A3717810594/A3647820061 and A3727810697 respectively will have the new style Shield Glass Guide and Optical Filter installed during production. INTERCHANGEABILITY CHART: OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
  • Page 491 TECHNICAL SERVICE BULLETIN CUSTOMER SERVICE GROUP BULLETIN NUMBER: 4027/4527/5035/5535/4022/4522 - 042 08/29/97 APPLICABLE MODEL: FT5035/5535/4027/4527/4022/4522 SUBJECT: SC302, 346, 354, 544, 547 SYMPTOM: A blank copy with a slightly dirty background, may accompany one of the following service codes: SC302, 346, 354, 544, 547. CAUSE: The Ground Brush does not come in contact with the Hot Roller and Pressure Rollers because the brack et of the brush is bent or the brush itself is deform.

  • Page 492: Service Manual

    A207 (FT5840) A208/A211 (FT5632/5832) 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 493 LEGEND PRODUCT CODE COMPANY RICOH SAVIN GESTETNER A207 (FT5840) 9400D CMR402 A208 (FT5632) 9032 CMR321 A211 (FT5832) 9032D CMR322 A206 (FT5740) N/A 9400L CMR401A A204 (FT5640) N/A 9400 N/A CMR401 A210 (FT5732) N/A 9032L CMR321A...
  • Page 494 IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY 1. Before disassembling or assembling parts of the copier and peripherals, make sure that the copier power cord is unplugged. 2. The wall outlet should be near the copier and easily accessible. 3. Note that some components of the copier and the paper tray unit are supplied with electrical voltage even if the main switch is turned off.
  • Page 495 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. (These are non-toxic supplies.) 3.
  • Page 496 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 (Section to refer to in (A204/A206/A207/...
  • Page 497 Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160) the Service Manual) 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) charge roller, the new charge...
  • Page 498 Item (A204/A206/A207/ (A153/A155/A156/ (Section to refer to in the Service Manual) A208/A210/A211) A157/A159/A160) 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 499: Optics Cooling Fan

    Item (A204/A206/A207/ (A153/A155/A156/ (Section to refer to in the Service Manual) A208/A210/A211) A157/A159/A160) 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 500 Item (A204/A206/A207/ (A153/A155/A156/ (Section to refer to in the Service Manual) A208/A210/A211) A157/A159/A160) 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 Pg 2-77 Paper Tray...
  • Page 501 Item (A204/A206/A207/ (A153/A155/A156/ (Section to refer to in the Service Manual) A208/A210/A211) A157/A159/A160 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 325 mm —...
  • Page 502 Item (Section to refer to in (A204/A206/A207/ (A153/A155/A156/ A208/A210/A211) A157/A159/A160 the Service Manual) 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. In the UP mode, settings such as front cover with an original image/blank back cover can be...
  • Page 503 Section 1 Overall Machine Information...
  • Page 504 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" x17" (Paper trays) Minimum: A5/8 "...
  • Page 505 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) Power Consumption:...
  • Page 506 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") 655 mm (25.8")
  • Page 507 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 508 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...
  • Page 509 MACHINE CONFIGURATION 2. MACHINE CONFIGURATION 2.1 COPIER A204V500.wmf A207/A208/A211...

  • Page 510: Optional Equipment

    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...
  • Page 511 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 512 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 513: Exhaust Fan

    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. Duplex Friction Roller 7.

  • Page 514: Electrical Component Descriptions

    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. Printed Circuit Boards Main Control Controls all copier functions both directly or...
  • Page 515 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 516 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 517 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 518 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 519 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" section for details.
  • Page 520 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 521 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 522 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 523 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 524 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 None...
  • Page 525 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 68 ~ 100 62 ~ 100...
  • Page 526 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 527 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) Pattern...
  • Page 528 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 529 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 ≥ 2s Y e s Drum Drive, Development Clutch, Toner Supply Clutch,...
  • Page 530 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 Component Used...
  • Page 531 Development bias, drum charge voltage, and exposure lamp voltage NOTE: Only items marked with are different from A153, A155, A156, A157, A159, and A160 copiers. The following table shows how process control affects development bias, drum charge, and exposure lamp voltages for various machine operations.
  • Page 532 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 533: Scanner Drive

    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 A208/A210/A211...
  • Page 534 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...

  • Page 535: Paper Feed And Registration

    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 536 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. Main Fusing Lamp 11.
  • Page 537 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 538 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 539 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 540 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. Optional Margin Adjustment Function Decal ....1 5.
  • Page 541 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...
  • Page 542 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. 2) Proper reinstallation of the shipping retainers is required in order to avoid any transport damage.
  • Page 543 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 544 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. Turn the "A1" lever [D] counterclockwise to lower the transfer belt unit. Then remove the cushion sheet [E].
  • Page 545 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. Remove the knob screw [E] and disconnect the white connector [F]. 14.
  • Page 546 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 547 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. 20.
  • Page 548 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 549 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 550 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 551 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 552 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 553 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 554 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 555 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 556 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 557 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 558 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 559 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 560 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...
  • Page 561 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 562 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 563 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 564 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 † 2-203 Development Bias Adjustment (for making V patterns)
  • Page 565 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 566 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. Do not change the factory setting. 5-505 Used in Japan only.
  • Page 567 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. °7-101-xxx Total Copies by Paper Size †...
  • Page 568 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 569 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 570 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 571 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 572 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 573 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 results.
  • Page 574 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 Detection...
  • Page 575 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 576 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 data sheet)
  • Page 577 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. Then press the key to make the adjustment.
  • Page 578 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 579 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 580 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 581 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 ° 5-305-001 Other versions automatically after the selected auto shut 1 ~ 999...
  • Page 582 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.) SP5-407-002: Deletes all the user code...
  • Page 583 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. Press the key to stop the free run.
  • Page 584 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 • °5-907 image added to copies in cover mode.
  • Page 585 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 586 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. ON: The staple indicator will go out after the following limit number of pages has been stacked and stapling will °6-104...
  • Page 587 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 588 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 589 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 590 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 591 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. "SC Counter Clear") Original Jam Resets the total original jam counter...
  • Page 592 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 2nd tray SP7-816-004 4th tray...
  • Page 593 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 Maximum Copy Quantity...
  • Page 594 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 595 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 596 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. See Note 1. Feed Roller Bottom Plate Pad Mylars...
  • Page 597 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 Replace if necessary Toner Supply Unit...
  • Page 598 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 Cleaning Roller...
  • Page 599 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 Bin and Paper Sensors...

  • Page 600: Regular Pm Procedure

    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. 2.
  • Page 601 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 602 PREVENTIVE MAINTENANCE SCHEDULE 7. Transfer Belt Unit 1. Remove the transfer belt and clean the used 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 603 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. SP3-112 Forced V Detection 4.

  • Page 604: Special Tools And Lubricants

    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 Silicone Grease - G40M...
  • Page 605 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 606 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...
  • Page 607 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...
  • Page 608 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 609 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 610: Hot Roller Replacement

    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 611 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 612 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 613 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 614 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 615 SECTION 2 AUTO REVERSE DOCUMENT FEEDER DF64 (A663) The DF64 (A663) ARDF is based on the DF61(A548) ARDF. Only the differences from the A548 are described in the following pages. Refer to the A548 ARDF section inside the A153/A155/A156/A157/A159/A160 copier service manual for other information.
  • Page 616 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 " x 8 "...
  • Page 617 DIFFERENCES FROM THE DF64 (A548) ARDF 2. DIFFERENCES FROM THE DF64 (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)
  • Page 618 SECTION 3 20-BIN SORTER STAPLER ST30 (A664)
  • Page 619 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) Paper for Bins: See the table below.
  • Page 620 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 621 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 622 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. Helical Wheels 13.
  • Page 623 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 624 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 625 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 626 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 627 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 628 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 629 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 630 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 631 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 632 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. When the main switch is turned on, the bin lift motor [E] lowers the bins (turns counterclockwise) until the bottom bin actuates the bin home position sensor.
  • Page 633 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. If the light path is blocked at the wrong time, a jam is detected.
  • Page 634 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 635 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 636 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 637 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 638: Stapler Unit

    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. In Top Slant mode, the stapler stays at the home position.
  • Page 639 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]. When the aligned copies are brought to the stapling position by the grip, the stapler motor starts rotating to staple the copies.
  • Page 640 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 641 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 642 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. A664D526.wmf –...

  • Page 643: Timing Charts

    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 644 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 300 ms...
  • Page 645 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 Adjustment Value...
  • Page 646 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...
  • Page 647 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 648 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...
  • Page 649 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 650 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 651 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 652 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]. 7.
  • Page 653 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. While still holding the bin rear plate straight, insert the front right guide pin [E] into guide slot [F].
  • Page 654 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. No good Good A664R514.wmf...

  • Page 655: Main Motor Removal

    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...
  • Page 656 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. Remove the grip assembly [A] (4 connectors, 3 screws). 3.
  • Page 657 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. Install the new main control board and connect all connectors. 4.
  • Page 658 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...
  • Page 659 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 660 REPLACEMENT AND ADJUSTMENT – Rear Long Helical Wheel – A664R528.wmf A664R527.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 661 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 662 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 663 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.
  • Page 664 SECTION 4 20-BIN SORTER STAPLER ST29 (A658)
  • Page 665 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) Bin Capacity:...
  • Page 666 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...
  • Page 667 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...
  • Page 668 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 Drives the bins Stapler...
  • Page 669 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. During copying, all rollers in the sorter stapler transport the paper at a speed which depends on the copier.
  • Page 670 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 671 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 672 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; the pins slide up and down in these slots. The other two pins fit into the slot in the helical wheels;...
  • Page 673 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 674 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 675 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 676 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 677 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 678 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 679 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...
  • Page 680 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 681 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. Remove the rear cover [B]. 2.
  • Page 682 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...
  • Page 683 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 684 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 685: Transport Motor Removal

    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...

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