Ricoh FT5535 User manual

SERVICE MANUAL
PN: RCFM5535
A156/A212...SERIES
RICOH GROUP COMPANIES
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

SERVICE MANUAL
A156/A212...SERIES
RICOH GROUP COMPANIES
®
®
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

A156/A153
A160/A157
A162/A161
FIELD
SERVICE MANUAL
Rev. 4/98
PN:RCFM5535
CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

It is the reader's responsibility when discussing the information contained within this
document to maintain a level of confidentiality that is in the best interest of Ricoh
Corporation and its member companies.
NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY
FASHION AND DISTRIBUTED WITHOUT THE PRIOR
PERMISSION OF RICOH CORPORATION.
All product names, domain names or product illustrations, including desktop images,
used in this document are trademarks, registered trademarks or the property of their
respective companies.
They are used throughout this book in an informational or editorial fashion only and for
the benefit of such companies. No such use, or the use of any trade name, or web
site is intended to convey endorsement or other affiliation with Ricoh products.
2000 RICOH Corporation. All rights reserved.
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LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A156 2635TD FT5535 9035DL
A153 2635 FT5035 9035
A160 2627TD FT4527 9027DL
A157 2627 FT4027 9027
A162 2822TD FT4522 9220DL
A161 2822 FT4022 9220
A207 2740TD FT5840 9400D
A208 2732 FT5632 9032
A211 2732TD FT5832 9032D
A206 CMR401A FT5740 9400L
A204 2740Z FT5640 9400
A210 CMR321A FT5732 9032L
A212 — FT4622 9122
A214 — FT4822 9122DL
DOCUMENTATION HISTORY
REV. NO. DATE COMMENTS
13/95Original printing
27/95A162/A161 addition
35/97A207/A208/A211 Addition
4 12/97 A212/A214 Addition
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.
The A211 copier is based on the A160 copier.
The A212 copier is based on the A161 copier.
The A214 copier is based on the A162 copier.
Only the differences from the base copiers are described in the
following pages. Therefore, this documentation should be treated
as an insert version of the base copier’s service manual, although
it has a separate binder. It should always be utilized together with
the base copier’s service manual.
Rev. 4/98
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CÓPIA NÃO CONTROLADA
CÓPIA NÃO CONTROLADA

The Field Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or certified
by successfully completing a Ricoh Technical
Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
WARNING
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Table of Contents
1. OVERALL MACHINE INFORMATION
1. SPECIFICATIONS.................................................................1-1
2. COMPONENT LAYOUT AND DESCRIPTION
1. MACHINE CONFIGURATION..............................................2-1
1.1 COPIER ........................................................................................2-1
1.2 OPTIONAL EQUIPMENT .............................................................2-2
2. MECHANICAL COMPONENT LAYOUT.............................2-3
3. PAPER PATH .....................................................................2-6
3.1 NORMAL COPYING......................................................................2-6
3.2 DUPLEX COPYING .....................................................................2-7
4. ELECTRICAL COMPONENT DESCRIPTIONS ..................2-8
5. DRIVE LAYOUT.................................................................2-13
5.1 ALL MODELS ............................................................................2-13
5.2 A153/A156 .................................................................................2-14
5.3 A157/A160...................................................................................2-14
3. INSTALLATION
1. INSTALLATION REQUIREMENTS .....................................3-1
1.1 ENVIRONMENT.............................................................................3-1
1.2 MACHINE LEVEL..........................................................................3-1
1.3 MINIMUM SPACE REQUIREMENTS ..........................................3-2
1.4 POWER REQUIREMENTS ...........................................................3-3
2. COPIER INSTALLATION.....................................................3-4
2.1 ACCESSORY CHECK ..................................................................3-4
2.2 COPIER INSTALLATION PROCEDURE ...............................3-5
2.3 PAPER SIZE SELECTION..........................................................3-13
2.3.1 Paper Feed Station Definition................................................................3-13
2.3.2 Paper Size Selection for Copier Paper Trays.......................................3-14
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2.3.3 Paper Size Selection for the Paper Tray Unit, LCT, and By-pass Feed............................................3-15
2.3.4 Special Paper Size Selection for the 1st Tray......................................3-16
2.4 SORTER ADAPTER INSTALLATION (OPTION FOR
A157, A159, AND A160 COPIERS ONLY) ................................3-17
2.4.1 Accessory Check....................................................................................3-17
2.4.2 Installation Procedure ............................................................................3-18
2.5 TRAY HEATER INSTALLATION (OPTION)...............................3-19
2.6 OPTICS ANTI-CONDENSATION HEATER (OPTION)...............3-21
2.7 ORIGINAL LENGTH SENSOR FOR APS (OPTION
ONLY FOR THE LT/DLT VERSION)..........................................3-23
2.8 ADS SENSOR (OPTION)............................................................3-24
2.9 KEY COUNTER HOLDER (OPTION) .........................................3-25
2.10 BRAND DECAL APPLICATION INSTRUCTIONS
(-10 AND -22 COPIERS ONLY) ...............................................3-26
4. SERVICE TABLES
1. SERVICE REMARKS...........................................................4-1
1.1 HANDLING THE DRUM................................................................4-1
1.2 DRUM UNIT...................................................................................4-2
1.3 DRUM CHARGE ROLLER............................................................4-2
1.4 OPTICS..........................................................................................4-3
1.5 ERASE LAMP................................................................................4-3
1.6 DEVELOPMENT UNIT ..................................................................4-4
1.7 TRANSFER BELT UNIT................................................................4-4
1.8 CLEANING SECTION IN THE DRUM UNIT.................................4-5
1.9 ERASE LAMP/PTL/QUENCHING LAMP .....................................4-5
1.10 PAPER FEED..............................................................................4-5
1.11 FUSING UNIT..............................................................................4-6
1.12 OTHERS......................................................................................4-6
2. SERVICE PROGRAM MODE ..............................................4-7
2.1 SERVICE PROGRAM MODE OPERATION.................................4-7
2.1.1 Service Program Mode Access Procedure.............................................4-7
2.1.2 Changing the Value of an SP Mode.........................................................4-8
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2.2 MEMORY RESET PROCEDURES ...............................................4-9
2.2.1 Resetting Counters...................................................................................4-9
2.2.2 Reset All Counters: SP7-808..................................................................4-10
2.2.3 Drum Initialization: SP3-123...................................................................4-11
2.2.4 Reset All Memory (SP5-801) ..................................................................4-12
2.3 SERVICE PROGRAM MODE TABLE ........................................4-14
2.3.1 Quick Reference......................................................................................4-14
2.3.2 SP Mode Table ........................................................................................4-19
2.4 UT MODE AND SP MODE CROSS REFERENCE TABLE........4-42
2.5 SP5-803 SENSOR/SWITCH INPUT CHECK..............................4-43
2.6 SP5-804 ELECTRICAL COMPONENT OUTPUT CHECK.........4-46
2.7 SP5-019 PAPER SIZE SETTING................................................4-48
2.7.1 Paper Size Selection for the Paper Tray Unit, LCT,
and By-pass Feed ...................................................................................4-48
2.7.2 Special Paper Size Selection for the 1st Tray......................................4-50
3. PRACTICAL SP MODE USE TABLE................................4-51
3.1 REPLACEMENT AND CLEANING.............................................4-51
3.2 MAJOR ADJUSTMENTS............................................................4-51
3.3 DATA DISPLAY...........................................................................4-52
4. TEST POINTS (MAIN CONTROL BOARD) ......................4-53
5. PREVENTIVE MAINTENANCE SCHEDULE ....................4-54
5.1 PM TABLE...................................................................................4-54
5.2 REGULAR PM PROCEDURE ....................................................4-60
6. SPECIAL TOOLS AND LUBRICANTS .............................4-64
5. REPLACEMENT AND ADJUSTMENT
1. INNER AND OUTER COVERS............................................5-1
1.1 OUTER COVER REMOVAL..........................................................5-1
1.1.1 Front Cover................................................................................................5-1
1.1.2 Rear Cover.................................................................................................5-1
1.1.3 Left Cover..................................................................................................5-1
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1.1.4 Front Right Cover .....................................................................................5-2
1.1.5 Rear Right Cover.......................................................................................5-2
1.1.6 Top Cover ..................................................................................................5-2
1.1.7 Operation Panel ........................................................................................5-2
1.2 INNER COVER REMOVAL ..........................................................5-3
1.2.1 Upper Inner Cover ....................................................................................5-3
1.2.2 Lower Right Inner Cover..........................................................................5-3
1.2.3 Lower Left Inner Cover.............................................................................5-3
2. OPTICS.................................................................................5-4
2.1 EXPOSURE GLASS REMOVAL...................................................5-4
2.2 EXPOSURE LAMP REPLACEMENT ...........................................5-5
2.3 SCANNER DRIVE BELT REPLACEMENT ..................................5-6
2.4 SCANNER POSITIONING ADJUSTMENT ..................................5-9
2.5 3RD SCANNER MOTOR REPLACEMENT................................5-10
2.6 LENS VERTICAL DRIVE MOTOR REPLACEMENT .................5-11
3. DEVELOPMENT AND TONER SUPPLY .........................5-12
3.1 DEVELOPMENT UNIT REMOVAL.............................................5-12
3.2 DEVELOPER REPLACEMENT ..................................................5-13
3.3 TONER SUPPLY MOTOR REPLACEMENT..............................5-15
4. AROUND THE DRUM........................................................5-16
4.1 DRUM UNIT REMOVAL..............................................................5-16
4.2 DRUM REPLACEMENT..............................................................5-17
4.3 PICK-OFF PAWL REPLACEMENT............................................5-19
4.4 ID SENSOR BOARD REPLACEMENT ......................................5-20
4.5 DRUM CLEANING BLADE REPLACEMENT ..........................5-21
4.6 PTL BOARD REPLACEMENT....................................................5-23
4.7 QUENCHING LAMP REPLACEMENT .......................................5-24
4.8 ERASE LAMP REPLACEMENT.................................................5-25
4.9 DRUM CHARGE ROLLER REPLACEMENT .............................5-26
4.10 DRUM CHARGE ROLLER TERMINAL REPLACEMENT .......5-27
4.11 DRUM CHARGE ROLLER CLEANER
REPLACEMENT.......................................................................5-28
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5. TRANSFER BELT UNIT ................................................5-29
5.1 TRANSFER BELT UNIT REPLACEMENT.................................5-29
5.2 TRANSFER BELT REPLACEMENT ........................................5-30
5.3 TRANSFER BELT CLEANING BLADE
REPLACEMENT.........................................................................5-31
5.4 DISPOSING OF COLLECTED TONER ......................................5-32
6. PAPER FEED .................................................................5-33
6.1 BY-PASS PICK-UP, FEED, AND SEPARATION ROLLERS,
AND TORQUE LIMITER REPLACEMENT........................................5-33
6.2 PICK-UP, FEED, AND SEPARATION ROLLERS,
AND TORQUE LIMITER REPLACEMENT
(A153/A155/A156) ......................................................................5-33
6.3 LOWER PAPER FEED UNIT REPLACEMENT
(A153/A155/A156) ....................................................................5-34
6.4 UPPER PAPER FEED UNIT REPLACEMENT
(A153/A155/A156) .....................................................................5-35
6.5 PAPER FEED ROLLER REPLACEMENT
(A157/A159/A160) ...................................................................5-36
6.6 REGISTRATION SENSOR REPLACEMENT ............................5-37
6.7 PAPER FEED CLUTCH REPLACEMENT
(A157/A159/A160) .....................................................................5-38
7. LCT ...................................................................................5-39
7.1 LCT UNIT REMOVAL..................................................................5-39
7.2 LCT DRIVE BELT REPLACEMENT .........................................5-40
7.3 LCT MOTOR REPLACEMENT ..................................................5-41
8. FUSING ..............................................................................5-42
8.1 FUSING UNIT REMOVAL ..........................................................5-42
8.2 FUSING LAMP REPLACEMENT ............................................5-43
8.3 HOT ROLLER REPLACEMENT .............................................5-44
8.4 PRESSURE ROLLER AND CLEANING
ROLLER REPLACEMENT ........................................................5-45
8.5 THERMISTOR REPLACEMENT.................................................5-46
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8.6 THERMOFUSE REPLACEMENT ..............................................5-46
9. DUPLEX UNIT....................................................................5-47
9.1 FRICTION ROLLER REPLACEMENT .......................................5-47
9.2 DUPLEX FEED ROLLER REPLACEMENT ...............................5-48
9.3 DUPLEX FEED MOTOR REPLACEMENT ..............................5-49
10. COPY QUALITY ADJUSTMENT.....................................5-51
10.1 LIGHT INTENSITY ADJUSTMENT (SP4-001) .........................5-51
10.2 UNEVEN EXPOSURE ADJUSTMENT .....................................5-53
10.3 IMAGE AREA BIAS VOLTAGE ADJUSTMENT ......................5-54
10.3.1 Development Bias Adjustment (SP2-201-001) ...................................5-54
10.3.2 Highest ID Level Bias (Manual ID Level 7)
Adjustment (SP2-201-002)...................................................................5-55
10.4 TONER DENSITY ADJUSTMENT (SP2-203)...........................5-56
10.5 DETECT/FIXED/TD SENSOR TONER SUPPLY
MODE SELECTION (SP2-208-001).........................................5-57
10.6 AUTOMATIC ID SENSOR ADJUSTMENT (SP3-001) .............5-57
10.7 TONER SUPPLY RATIO SELECTION.....................................5-58
10.8 ADS SENSOR AUTOMATIC ADJUSTMENT
(SP4-201)............................................................................................5-59
10.9 ADS DENSITY SELECTION (SP5-106)....................................5-59
10.10 VERTICAL MAGNIFICATION ADJUSTMENT
(SP4-008)................................................................................5-60
10.11 HORIZONTAL MAGNIFICATION ADJUSTMENT (SP4-101) 5-61
10.12 FOCUS ADJUSTMENT IN FULL SIZE MODE
(SP4-103)............................................................................................5-62
10.13 FOCUS ADJUSTMENT IN ENLARGE/REDUCE
MODE (SP4-102)....................................................................5-62
10.14 LEAD EDGE REGISTRATION ADJUSTMENT (SP1-001) ....5-62
10.15 LEAD EDGE ERASE MARGIN ADJUSTMENT
(SP2-101-001) ........................................................................5-63
10.16 LENS HORIZONTAL H.P. ADJUSTMENT
(SP4-011-001~009)..................................................................5-63
10.17 4TH/5TH MIRROR HEIGHT ADJUSTMENT ..........................5-65
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11. OTHERS...........................................................................5-66
11.1 MAIN CONTROL BOARD REPLACEMENT............................5-66
11.2 AC POWER SUPPLY BOARD REPLACEMENT.....................5-67
11.3 DC POWER SUPPLY BOARD REPLACEMENT.....................5-68
11.4 CB HIGH VOLTAGE SUPPLY BOARD REPLACEMENT.......5-69
11.5 T HIGH VOLTAGE SUPPLY BOARD REPLACEMENT..........5-70
6. TROUBLESHOOTING
3. COPY QUALITY...................................................................6-1
3.1 INTRODUCTION............................................................................6-1
3.2 BLANK COPY (WHITE COPY) ....................................................6-2
3.3 DIRTY BACKGROUND.................................................................6-5
3.4 UNEVEN IMAGE DENSITY ..........................................................6-9
3.5 VERTICAL BLACK BANDS .......................................................6-10
3.6 VERTICAL BLACK LINES .........................................................6-11
3.7 VERTICAL WHITE LINES OR BANDS—1
(DULL OR BLURRED) ..............................................................6-12
3.8 VERTICAL WHITE LINES OR BANDS—2
(THIN, DISTINCT) ......................................................................6-13
3.9 HORIZONTAL BLACK/WHITE LINES ......................................6-14
3.10 SKEWED (OPTICAL) COPY IMAGE .......................................6-15
3.11 TONER DENSITY TOO HIGH ..................................................6-16
3.12 TONER DENSITY TOO LOW ...................................................6-18
3.13 TONER SCATTERING .............................................................6-20
3.14 UNFUSED COPY .....................................................................6-21
3.15 A HORIZONTAL THIN LINE APPEARING
CLOSE TO THE LEADING EDGE...........................................6-22
3.16 CREASING AFTER FUSING ....................................................6-22
3.17 Z-FOLDED COPY OR LEADING EDGE
REGISTRATION VARIES.........................................................6-22
4. TONER SUPPLY CONTROL ............................................6-23
3. SERVICE CALL CONDITIONS..........................................6-26
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3.1 SUMMARY...................................................................................6-26
3.2 SC CODE TABLE........................................................................6-26
3.3 WARNING SC CODE TABLE.....................................................6-28
3.4 C-CODE TABLE..........................................................................6-29
3.5 U-CODE TABLE..........................................................................6-29
3.6 SC CODE DESCRIPTIONS.........................................................6-30
4. BLOWN FUSE CONDITIONS............................................6-43
5. ELECTRICAL COMPONENT DEFECTS...........................6-44
5.1 SENSORS....................................................................................6-44
5.2 SWITCHES ..................................................................................6-47
APPENDIX
PROCESS CONTROL TABLE .................................................... 1
TABLES & SP MODES FOR PROCESS CONTROL ................. 2
AUTO PROCESS CONTROL TIMING CHART........................... 4
7. DOCUMENT FEEDER A548
1. SPECIFICATIONS................................................................7-1
2. COMPONENT LAYOUT.......................................................7-2
2.1 MECHANICAL COMPONENTS ..................................................7-2
2.2 ELECTRICAL COMPONENTS ...................................................7-3
3. ELECTRICAL COMPONENT DESCRIPTION.....................7-4
4. INSTALLATION....................................................................7-5
4.1 ACCESSORY CHECK ..................................................................7-5
4.2 INSTALLATION PROCEDURE.....................................................7-6
5. SERVICE TABLES...............................................................7-7
5.1 DIP SWITCHES.............................................................................7-7
5.2 VARIABLE RESISTORS...............................................................7-8
5.3 LED................................................................................................7-8
5.4 FUSE..............................................................................................7-8
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6. REPLACEMENT AND ADJUSTMENT .............................7-9
6.1 TRANSPORT BELT REPLACEMENT..........................................7-9
6.2 FEED ROLLER REPLACEMENT ..............................................7-10
6.3 FRICTION BELT REPLACEMENT.............................................7-11
6.4 ORIGINAL SET AND ORIGINAL WIDTH
SENSOR REPLACEMENT .......................................................7-12
6.5 VERTICAL REGISTRATION ADJUSTMENT ............................7-13
6.5.1 One Sided Thin Original Mode...............................................................7-13
6.5.2 Two Sided Original Mode ......................................................................7-14
6.6 SIDE-TO-SIDE REGISTRATION (DF POSITIONING)
ADJUSTMENT ...........................................................................7-15
8. PAPER TRAY UNIT A549/A550
1. SPECIFICATIONS................................................................8-1
2. COMPONENT LAYOUT.......................................................8-2
2.1 MECHANICAL COMPONENT LAYOUT ......................................8-2
2.2 DRIVE LAYOUT ............................................................................8-3
2.3 ELECTRICAL COMPONENT DESCRIPTION..............................8-4
3. INSTALLATION...................................................................8-5
3.1 ACCESSORY CHECK ..................................................................8-5
3.2 INSTALLATION PROCEDURE.....................................................8-6
3.3 TRAY HEATER (OPTION)............................................................8-8
4. SERVICE TABLES...............................................................8-9
4.1 DIP SWITCHES.............................................................................8-9
4.2 TEST POINTS..............................................................................8-10
5. REPLACEMENT AND ADJUSTMENT..............................8-11
5.1 EXTERIOR COVER REMOVAL..................................................8-11
5.2 PAPER FEED CLUTCH REPLACEMENT..................................8-12
5.3 PAPER FEED UNIT REPLACEMENT........................................8-13
5.4 FEED ROLLER, PICK-UP ROLLER, AND REVERSE ROLLER
REPLACEMENT..........................................................................8-14
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