Ricoh FT5535 User manual

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

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 the drum heater and the optional anti-condensation heaters are
supplied with electrical voltage even if the main switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers
off or open while the main switch is turned on, keep hands away from
electrified or mechanically driven components.
5. The inside and the metal parts of the fusing unit become extremely hot
while the copier is operating. Be careful to avoid touching those
components with your bare hands.
HEALTH SAFETY CONDITIONS
1. Toner and developer are non-toxic, but if you get either of them in your
eyes by accident, it may cause temporary eye discomfort. Try to remove
with eye drops or flush with water as first aid. If unsuccessful, get medical
attention.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The copier and its peripherals must be installed and maintained by a
customer service representative who has completed the training course
on those models.
!CAUTION
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.
FSM aFT5535/4527/4522

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1. Do not incinerate toner cartridges or used toner. Toner dust may ignite
suddenly when exposed to open flame.
2. Dispose of used toner, developer, and organic photoconductors in
accordance with local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries (from the main control boards) in
order to dispose of them later, do not store more than 100 batteries (from
the main control boards) per sealed box. Storing larger numbers or not
sealing them apart may lead to chemical reactions and heat build-up.
FT5535/4527/4522 bFSM

SECTION 1
OVERALL MACHINE
INFORMATION

1. SPECIFICATIONS
Configuration: Desktop
Copy Process: Dry electrostatic transfer system
Originals: Sheet/Book
Original Size: Maximum A3/11" x 17"
Copy Paper Size: Maximum
A3/11" x17" (Paper trays)
Minimum
A5/81/2" x 51/2" sideways (Paper trays)
A4/11" x 81/2" sideways (LCT)
A6/51/2" x 81/2" lengthwise (By-pass)
Duplex Copying: Maximum
A3/11" x 17"
Minimum
A5/81/2" x 51/2" (sideways)
Copy Paper Weight: Paper tray:
52 ~ 128 g/m2, 14 ~34 lb
(A153, A155, and A156 copiers)
64 ~ 90 g/m2, 17 ~ 24 lb
(A157, A159, and A160 copiers)
By-pass:
52 ~ 157 g/m2, 14 ~42 lb
LCT: 52 ~ 128 g/m2, 14 ~ 34 lb
Duplex copying:
64 ~ 105 g/m2, 17 ~ 24 lb
Reproduction Ratios: 4 Enlargement and 6 Reduction
A4/A3 Version LT/DLT Version
Enlargement
200%
141%
122%
115%
200%
155%
129%
121%
Full size 100% 100%
Reduction
93%
82%
75%
71%
65%
50%
93%
85%
77%
74%
65%
50%
Power Source: 120V/60Hz:
More than 12 A (for North America)
Rev. 7/95
FSM 1-1 FT5535/4527/4522

Power Consumption:
A153, and A156 copiers A157, and A160 copiers
Copier Only Full System Copier Only Full System
Maximum 1.45 KW 1.50 KW 1.45 KW 1.50 KW
Copying 1.00 KW 1.00 KW 0.80 KW 0.80 KW
Warm-up 0.90 KW 0.92 KW 0.90 KW 0.92 KW
Stand-by 0.16 KW 0.19 KW 0.15 KW 0.17 KW
Energy
Saver
1 0.15 KW 0.17 KW 0.14 KW 0.16 KW
2 0.13 KW 0.15 KW 0.12 KW 0.13 KW
3 0.12 KW 0.14 KW 0.09 KW 0.10 KW
4 0.11 KW 0.12 KW 0.07 KW 0.08 KW
5 0.09 KW 0.11 KW 0.05 KW 0.06 KW
6 0.07 KW 0.09 KW – –
Auto Off 0.02 KW 0.04 KW 0.02 KW 0.04 KW
NOTE: 1) Full System: Copier + ADF + Paper Tray Unit + 20 Bin S/S
2) Energy Saver: See SP1-105-002
3) Auto Off: See SP5-305
A161 and A162 Copiers
Copier Only Full System
Maximum 1.45 KW 1.50 KW
Copying 0.64 KW 0.72 KW
Warm-up 0.95 KW 0.97 KW
Stand-by 0.15 KW 0.17 KW
Energy Saver
1 0.14 KW 0.16 KW
2 0.12 KW 0.13 KW
3 0.09 KW 0.10 KW
4 0.07 KW 0.08 KW
5 0.05 KW 0.06 KW
Auto Off 0.02 KW 0.04 KW
NOTE: 1) Full System: Copier + ADF + Paper Tray Unit + 10 Bin S/S
2) Energy Saver: See SP1-105-002
3) Auto Off: See SP5-305
Noise Emission:
A153, and A156 copiers A157, and A160 copiers
Copier Only Full System* Copier Only Full System*
1. Sound Power Level
Copying 66 dB(A) 68 dB(A) 61 dB(A) 67 dB(A) (LWA)
Warm-up 41 dB(A) 41 dB(A) 39 dB(A) 40 dB(A) (LWA)
Stand-by 41 dB(A) 41 dB(A) 39 dB(A) 40 dB(A) (LWA)
2. Sound Pressure Level at the operator position
Copying 58 dB(A) 57 dB(A) 54 dB(A) 56 dB(A) (LPA)
Warm-up 33 dB(A) 27 dB(A) 32 dB(A) 27 dB(A) (LPA)
Stand-by 33 dB(A) 27 dB(A) 32 dB(A) 27 dB(A) (LPA)
NOTE: The above measurements are to be made according to ISO 7779.
* : Full System: Copier + ADF + Paper Tray Unit +10 Bin S/S.
Rev. 7/95
FT5535/4527/4522 1-2 FSM

Dimensions:
Width Depth Height
A153 copier 1030 mm (40.6") 655 mm (25.8") 606 mm (23.9")
A157/A161 copier 900 mm (35.5") 655 mm (25.8") 606 mm (23.9")
A156 copiers 1258 mm (49.6") 655 mm (25.8") 606 mm (23.9")
A160/A162 copiers 1128 mm (44.5") 655 mm (25.8") 606 mm (23.9")
Measurement Conditions
1) With by-pass feed table closed
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)
FT4522 A162 copier About 80 kg (176.4 lb)
Zoom: From 50% to 200% in 1% steps
Copying Speed (copies/minute):
A4 sideways/
11" x 81/2"A3/11" x 17" B4/81/2" x 14"
A153, and A156
copiers 35 20/19 22
A157, and A160
copiers 27 15/14 17
A161, and A162
copiers 22 12 -
Warm-Up Time A153, and A156 copiers:
Less than 110 seconds (20°C)
A157, and A160 copiers:
Less than 80 seconds (20°C)
A161, and A162 copiers:
Less than 60 seconds (20°C)
First Copy Time:
Paper Feed Station A4/11" x 81/2" (sideways)
A153, and A156
copiers A157, and A160 copiers A161 and A162 copiers
1st Tray 5.2 s (except for A156) 5.9 s (except for A160) 5.9 s (except for A162)
2nd Tray 5.7 s 6.6 s 6.6 s
By-pass 4.8 s 5.6 s 5.6 s
LCT 5.0 s 5.9 s 5.9 s
Note: In A156 and A160 copiers, the 2nd tray in the above table is called the
1st tray (see Installation - Paper Feed Station Definition).
Rev. 7/95
FSM 1-3 FT5535/4527/4522

Copy Number Input: Ten-key pad, 1 to 999 (count up or count down)
Manual Image Density
Selection: 7 steps
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.
Copy Paper Capacity:
Paper Tray By-pass Feed LCT
A153 copier About 500 sheets x2 About 40 sheets –
A156 copier About 500 sheets x1 About 40 sheets About 1000 sheets
A157 copier About 250 sheets x2 About 40 sheets –
A160 copier About 250 sheets x1 About 40 sheets About 1000 sheets
A161 copier About 250 sheets x2 About 40 sheets –
A162 copier About 250 sheets x1 About 40 sheets About 1000 sheets
Duplex Tray Capacity
[A156/A160/A162]: 50 sheets (30 sheets for A3/11"x17" 81 ~ 105g/m2, 21.5 ~ 27.9 lb paper)
Toner Replenishment: Cartridge exchange (415 g/cartridge)
Toner Yield: 17K Copies/cartridge
Developer Replenisment: Type 1 (1Kg.)
Developer Yield: A153/A156 @ 120K
A157/A160 @ 100K
A161/A162 @ 100K
Optional Equipment: •Platen cover
•Document feeder
•Paper tray unit with two paper trays
•Paper tray unit with three paper trays
•10 bin micro sorter
•20 bin mini sorter
•10 bin sorter stapler
•20 bin sorter stapler(Not used with A161/A162 copiers)
•Sorter adapter (required when installing 20 bin
mini sorter, 10 bin sorter stapler, or 20 bin sorter
stapler for A157, A160, A161, and A162 copiers)
•Key counter
•Tray heater
•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
•Zoom (10 Key) Function Decal *
•Margin Adjustment Function Decal*
Rev. 7/95
*Not used on FT4022/4522 (A161/A162)
FT5535/4527/4522 1-4 FSM

SECTION 2
COMPONENT LAYOUT AND
DESCRIPTION

1. MACHINE CONFIGURATION
1.1 COPIER
Rev. 7/95
FSM 2-1 FT5535/4527/4522

1.2 OPTIONAL EQUIPMENT
* Only available on models FT5535 and FT4527
** Not for use on FT4022/4522(A161/A163) copiers.
Rev. 7/95
FT5535/4527/4522 2-2 FSM

2. MECHANICAL COMPONENT LAYOUT
– A156 copier –
NOTE: 1. The A153 copier is the same as the A156 copier except that the A153
does not have a duplex tray or an LCT.
2. The A155 copier is the same as the A156 copier except that the A155
does not have a duplex tray.
14
5
30
31
32
33
34
35
36
37
38
1
2
3
4
28 27 26 25 24 23
22
21
20
19
18
17
16
13
12
11
1098
7
6
29
15
FSM 2-3 FT5535/4527/4522

– A160/A162 copier –
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.
Rev. 7/95
14
5
30
31
32
33
34
35
36
37
38
1
2
3
4
28 27 26 25 24 23
22
21
20
19
18
17
16
13
12
11
1098
7
6
29
15
FT5535/4527/4522 2-4 FSM

1. 3rd Mirror
2. 2nd Mirror
3. 1st Mirror
4. Exposure Lamp
5. Lens
6. Quenching Lamp
7. Drum Cleaning Blade
8. Drum Charge Roller
9. 6th Mirror
10. OPC Drum
11. Erase Lamp
12. 4th Mirror
13. 5th Mirror
14. Toner Supply Unit
15. Pre-transfer Lamp
16. Development Unit
17. Registration Rollers
18. Feed Roller
19. Pick-up Roller
20. Separation Roller
21. Large Capacity Tray
22. Vertical Transport Rollers
23. Paper Feed Roller
The roller for A153/A156
copiers is different from that
for A157/160/161/162 copiers.
24. Friction Pad
25. Duplex Friction Roller
26. Duplex Feed Roller
27. Jogger Fence
28. Transfer Belt
29. Transfer Belt Cleaning Blade
30. Lower Paper Tray
31. End Fence
32. Entrance Rollers
33. Pick-off Pawls
34. Pressure Roller
35. Hot Roller
36. Junction Gate
37. Hot Roller Strippers
38. Transport Fan
Rev. 7/95
FSM 2-5 FT5535/4527/4522

3. PAPER PATH
3.1 NORMAL COPYING
– A156 copier –
–A160/A162 copier –
Rev. 7/95
FT5535/4527/4522 2-6 FSM

3.2 DUPLEX COPYING
– A156 copier –
– A160/A162 copier –
Rev. 7/95
FSM 2-7 FT5535/4527/4522

4. ELECTRICAL COMPONENT DESCRIPTIONS
Refer to the electrical component layout and the point to point diagram on the
waterproof paper in the pocket for symbols and index numbers.
Symbol Index
No. Description Note
Printed Circuit Boards
PCB1 14 Main Control Controls all copier functions both directly or
through other control boards.
PCB2 12 AC Drive Provides ac power to the exposure lamp and
fusing lamps.
PCB3 11 DC Power Supply Provides dc power.
PCB4 96 Main Motor Control Controls the rotation of the main motor.
PCB5 1 CB High Voltage
Supply Supplies high voltage to the drum charge roller and development roller.
PCB6 55 T High Voltage Supply Supplies high voltage to the transfer belt.
PCB7 3 Operation Panel Controls the LED matrix, and monitors the key
matrix.
PCB8 8 Noise Filter (220 ~ 240
V machines only) Removes electrical noise.
PCB9 63 Duplex Control
(Duplex machines only) Controls the operation of the duplex tray.
PCB10 6 Liquid Crystal Display
(A156 machines only) Controls the guidance display and displays guidance for machine operation.
PCB11 102 LCT Interface
(LCT machines only) Interfaces the LCT control signal between the main board and the LCT.
Motors
M1 88 Main Drives the main unit components.
M2 79 Toner Bottle Drive Rotates the toner bottle to supply toner to the
toner supply unit.
M3 97 Upper Tray Lift
(A153 machines only) Raises the bottom plate in the upper paper tray.
M4 86 Lower Tray Lift (A153/A156 machines
only)
Raises the bottom plate in the lower paper tray.
M5 99 LCT Lift
(LCT machines only) Lifts up and lowers the LCT bottom plate.
M6 94 Optics Cooling Fan 1 Removes heat from the optics unit.
M7 95 Optics Cooling Fan 2 (A153/A156 machines
only)
Removes heat from the optics unit.
M8 89 Exhaust Fan 1 Removes the heat from around the fusing unit.
M9 90 Exhaust Fan 2 (A153/A156 machines
only)
Removes the heat from around the fusing unit.
M10 92 Scanner Drive Drives the 1st and 2nd scanners (dc stepper
motor).
M11 78 3rd Scanner Drive Drives the 3rd scanner (dc stepper motor).
M12 87 Lens Vertical Drive Shifts the lens vertical position.
M13 77 Lens Horizontal Drive Shifts the lens horizontal position.
M14 58 Duplex Feed
(Duplex machines only) Drives the feed roller and moves the bottom plate up and down.
M15 61 End Fence Jogger
(Duplex machines only) Drives the end fence jogger to square the paper stack.
FT5535/4527/4522 2-8 FSM

Symbol Index
No. Description Note
M16 60 Side Fence Jogger
(Duplex machines only) Drives the side fence jogger to square the paper stack.
Sensors
S1 27 By-pass Feed Paper
Width Informs the CPU what width paper is in the by-pass feed table.
S2 31 By-pass Feed Paper
End Informs the CPU that there is no paper in the by-pass tray.
S3 51 Upper Tray Paper End (Non-duplex machines
only)
Informs the CPU when the upper paper tray
runs out of paper.
S4 107 Upper Relay Detects the leading edge of paperfrom the upper tray to determine the stop timing of the
upper paper feed clutch, and detects misfeeds.
S5 29 Upper Tray Upper Limit (A153/ machines only) Detects the height of the paper stack in the upper paper tray to stop the upper tray lift
motor.
S6 52 Lower Tray Paper End Informs the CPU when the lower paper tray
runs out of paper.
S7 106
Lower Relay Detects the leading edge of paper from the
lower paper tray to determine the stop timing of
the lower paper feed clutch, and detects
misfeeds.
S8 30 Lower Tray Upper Limit (A153/A156 machines
only)
Detects the height of the paper stack in the
lower paper tray to stop the lower tray lift motor.
S9 100 LCT Lower Limit
(LCT machines only) Sends a signal to the CPU to stop lowering the LCT bottom plate.
S10 26 LCT Paper End
(LCT machines only) Informs the CPU when the LCT runs out of paper.
S11 28 LCT Upper Limit
(LCT machines only) Sends a signal to the CPU to stop lifting the LCT bottom plate.
S12 28 Registration Detects the leading edge of the copy paper to determine the stop timing of the paper feed
clutch, and detects misfeeds.
S13 50 Image Density
(ID) Detects the density of various patterns on the drum during process control.
S14 53 Toner Density
(TD) Detects the amount of toner inside the development unit.
S15 39 Lens Horizontal HP Informs the CPU that the lens is at the
horizontal home position.
S16 20 Lens Vertical HP Informs the CPU that the lens is at the full-size
position.
S17 15 Scanner HP Informs the CPU when the 1st and 2nd
scanners are at the home position.
S18 24 3rd Scanner HP Informs the CPU when the 3rd scanner is at
the home position.
S19 21 Original Length-2 Detects the length of the original. This is one of
the APS (Auto Paper Select) sensors.
S20 45 Fusing Exit Detects misfeeds.
S21 16 Platen Cover Informs the CPU whether the platen cover is up or down (related to APS/ARE functions).
ARE: Auto Reduce and Enlarge
S22 54 Toner End Instructs the CPU to add toner to the toner
supply unit, and detects toner end conditions.
Rev. 7/95
FSM 2-9 FT5535/4527/4522

Symbol Index
No. Description Note
S23 43 Auto Response (Not used on A161/A162
copiers
Returns the operation panel display and exits
from the energy saver mode.
S24 23 Transfer Belt Contact HP Informs the CPU of the current position of both the transfer belt unit and the drum charge roller
unit.
S25 13 Auto Image Density
(ADS Sensor) Detects the backgrounddensity of each original in ADS mode.
S26 44 Original Width Detects the width of the original. This is one of
the APS (Auto Paper Select) sensors.
S27 19 Original Length-1 Detects the length of the original. This is one of
the APS (Auto Paper Select) sensors.
S28 56 Duplex Paper End
(Duplex machines only) Detects paper in the duplex tray.
S29 57 Duplex Turn (Duplex machines only) Detects the trailing edge of the copy paper to determine the jogging timing, and detects
misfeeds.
S30 62 Duplex Entrance
(Duplex machines only) Detects misfeeds.
S31 59 Side Fence Jogger HP
(Duplex machines only) Detects the home position of the duplex side fence jogger.
S32 64 End Fence Jogger HP
(Duplex machines only) Detects the home position of the duplex end fence jogger.
S33 22 Original Length (Option for N.
American models)
Detects original length for 11" x 15" paper.
Switches
SW1 33 By-pass Feed Table Detects whether theby-pass feed table is open
or closed.
SW2 36 Upper Tray (Non-duplex machines
only)
Detects whether the upper paper tray is in
place or not.
SW3 35 Lower Tray Detects whether the lower paper tray is in
place or not.
SW4 104 Tray Down
(LCT machines only) Sends a signal to the CPU to lower the LCT bottom plate.
SW5 25 Upper Tray Paper Size (Non-duplex machines
only)
Determines what size of paper is in the upper
paper tray.
SW6 34 Lower Tray Paper Size Determines what size of paper is in the lower
paper tray.
SW7 32 Vertical Guide Set (Non-LCT machines
only)
Detects whether the vertical guide is open or
not.
SW8 105 LCT Cover-1
(LCT machines only) Detects whether the LCT cover is open or not.
SW9 103 LCT Cover-2
(LCT machines only) Cuts the dc power line of the LCT lift motor.
SW10 42 Main Supplies power to the copier.
SW11 41 Front Cover Safety Detects whether the front door is open and via
relays cuts the ac power.
SW12 48 Exit Cover Safety
(A157/A160machinesonly) Detects whether the exit cover is open or not.
Rev. 7/95
FT5535/4527/4522 2-10 FSM

Symbol Index
No. Description Note
Magnetic Clutches
CL1 72 Toner Supply Turns the toner supply roller to supply toner to
the development unit.
CL2 71 Development Drives the development roller.
CL3 93 Transfer Belt Contact (1/3 Turn Clutch) Controls the touch and release movement of both the transfer belt unit and the drum charge
roller unit.
CL4 73 Registration Drives the registration rollers.
CL5 74 By-pass Feed Starts paper feed from the by-pass feed table
or LCT.
CL6 76 Relay Drives the relay rollers.
CL7 84 Upper Paper Feed (Non-duplex machines
only)
Starts paper feed from the upper paper tray.
CL8 85 Lower Paper Feed Starts paper feed from the lower paper tray.
Solenoids
SOL1 75
LCT machines:
LCT/By-Pass Pick-up
Solenoid
Non-LCT machines:
By-pass Pick-up
Solenoid
Picks paper up from the by-pass feed table.
When paper is fed from the LCT, this solenoid
assists SOL3.
SOL2 91 Junction Gate
(Duplex machines only) Moves the junction gate to direct copies to the duplex tray or to the paper exit.
SOL3 98 LCT Pick-up
(LCT machines only) Picks up paper from the LCT.
SOL4 80 Upper Tray Pick-up
(A153 machines only) Controls the up/down movement of the pick-up roller in the upper paper tray.
SOL5 82 Lower Tray Pick-up (A153/A156 machines
only)
Controls the up/down movement of the pick-up
roller in the lower paper tray.
SOL6 81 Upper Tray Separation (A153 machines only) Controls the up-down movement of the separation roller in the upper paper tray feed
station.
SOL7 83 Lower Tray Separation (A153/A156 machines
only)
Controls the up-down movement of the
separation roller in the lower paper tray feed
station.
Lamps
L1 17 Exposure Applies high intensity light to the original for
exposure.
L2 65 Main Fusing Provides heat to the central area of the hot
roller.
L3 66 Secondary Fusing Provides heat to bothends of the hot roller.
L4 4 Pre-transfer Reduces the charge remaining onthe drum surface before transfer.
L5 5 Quenching Neutralizes any charge remaining on the drum surface after cleaning.
L6 2 Erase After exposure, this eliminates the charge on areas of the drum that will not be used for the
image.
FSM 2-11 FT5535/4527/4522