Ricoh 5535 F Service 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 a FT5535/4527/4522

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 b FSM

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 Copyi ng : Maximu m

A3/11" x 17"

Minimum

A5/81/2" x 51/2" (sideways)

Rev. 7/95

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 copyi ng :

64 ~ 105 g/m2, 17 ~ 24 lb

Reproduction Ratios: 4 Enlargement and 6 Reduction

A4/A3 Version LT/DLT Version

200%

Enlargem ent

Full size 100% 100%

Reduction

141% 122% 115%

93% 82% 75% 71% 65% 50%

200% 155% 129% 121%

93% 85% 77% 74% 65% 50%

Power Source: 120V/60Hz:

More than 12 A (for North America)

FSM 1-1 FT5535/4527/4522

Rev. 7/95

Power Consumption:

A153, and A156 copiers A157, and A160 copiers

Copier Only Full System Copier Only Full System

Maximum 1.45 KW 1.50 KW 1.45 KW 1.50 KW

Copying 1.00 KW 1.00 KW 0.80 KW 0.80 KW Warm-up 0.90 KW 0.92 KW 0.90 KW 0.92 KW Stand-by 0.16 KW 0.19 KW 0.15 KW 0.17 KW

1 0.15 KW 0.17 KW 0.14 KW 0.16 KW

Energy

Saver

Auto Off 0.02 KW 0.04 KW 0.02 KW 0.04 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 – –

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

1 0.14 KW 0.16 KW

Energy Saver

Auto Off 0.02 KW 0.04 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

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) (L Warm-up 41 dB(A) 41 dB(A) 39 dB(A) 40 dB(A) (L Stand-by 41 dB(A) 41 dB(A) 39 dB(A ) 40 dB(A) (L

2. Sound Pressure Level at th e ope rator posi tion

Copying 58 dB(A) 57 dB(A) 54 dB(A) 56 dB(A) (L Warm-up 33 dB(A) 27 dB(A) 32 dB(A) 27 dB(A) (L Stand-by 33 dB(A) 27 dB(A) 32 dB(A ) 27 dB(A) (L

WA) WA) WA)

PA) PA) PA)

NOTE: The above measur ements are to be made according to ISO 7779.

* : Full System: Copier + ADF + Paper Tray Unit +10 Bin S/S.

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:

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)

Rev. 7/95

Weight

Zoom: From 50% to 200% in 1% steps Copying Speed (copies/minute):

A153, and A156

copiers

A157, and A160

copiers

A161, and A162

copiers

A4 sideways/

11" x 8

1/2"

35 20/19 22

27 15/14 17

22 12 -

A3/11" x 17" B4/8

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:

A4/11" x 8

Paper Feed Station

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

A153, and A156

copiers

1/2" (sideways)

A157, and A160

copiers

1/2" x 14"

A161 and A162

copiers

Note: In A156 and A160 copie rs, the 2nd tray in the above table is calle d the

1st tray (see Installation - Paper Feed Station Definition).

FSM 1-3 FT5535/4527/4522

Rev. 7/95

Copy Number Input: Ten-key pad, 1 to 999 (count up or count down) Manual Image Density

7 steps Selection: Automatic Reset: 1 minute is the standard setting; it can be changed to

a maximum of 999 seconds or no auto reset by SP

mode. 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 Tr ay Cap acity [A156/A160/A162]:

50 sheets (30 sheets for A3/11"x17"

81 ~ 105g/m2, 21.5 ~ 27.9 lb paper) Toner Replenishment: Cartridg e exchange (415 g /car tridge)

Toner Yield: 17K Copies/cartridge Developer Replenisment: Type 1 (1Kg.) Developer Yie ld: 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

• Ori ginal lengt h sen sor for 11" x 15" size pape r

(only for LT/ DLT versi o n)

• 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 1-4 FSM

SECTION 2

COMPONENT LAYOUT AND

DESCRIPTION

1. MACHINE CONFIGURATION

1.1 COPIER

Rev. 7/95

FSM 2-1 FT5535/4527/4522

Rev. 7/95

1.2 OPTIONAL EQUIPMENT

* Only available on models FT5535 and FT4527 ** Not for use on FT4022/4522(A161 /A163) copiers.

FT5535/4527/4522 2-2 FSM

2. MECHANICAL COMPONENT LAYOUT

201918

171613

– A156 copier –

4 3

38 37

36 35 34

33 32

28 27 26

24 23

1098

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.

FSM 2-3 FT5535/4527/4522

Rev. 7/95

20191817161312

– A160/A162 copier –

4 3

38 37

35 34 33 32

1098

NOTE: The A157/A161 copiers are the sa me as the A160/A162 copiers e xcept

that the A157and A161 do not have a duplex tray or an LCT.

FT5535/4527/4522 2-4 FSM

Rev. 7/95

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

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

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

33. Pick-off Pawls

34. Pressure Roller

35. Hot Roller

36. Junction Gate

37. Hot Roller Strippers

38. Transport Fan

FSM 2-5 FT5535/4527/4522

Rev. 7/95

3. PAPER PATH

3.1 NORMAL COPYING

– A156 copier –

–A160/A162 copier –

FT5535/4527/4522 2-6 FSM

Rev. 7/95

3.2 DUPLEX COPYING

– A156 copier –

– A160/A162 copier –

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 pape r in the pocket for symbols and index numbers.

Symbol

Printed Circuit Boards

PCB1 14

PCB2 12 PCB3 1 1 DC Power Supply Provi des dc power.

PCB4 9 6 Main Motor Control Controls the rotation of the mai n motor. PCB5 1 PCB6 5 5 T High Voltage Supply Supplies high voltage to the transfer belt. PCB7 3

PCB8 8

PCB9 63

PCB10 6

PCB11 102

Motors

M1 88 Main Drives the main unit components. M2 79

M3 97

M4 86

M5 99 M6 94 Optics Cooling Fan 1 Removes heat from the optics unit.

M7 95

M8 89 Exhaust Fan 1 Removes the heat from around the fusing unit.

M9 90

M10 92 M11 78 3rd Scanner Drive Drive s 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

M15 61

Ind ex

No.

Description Note

Main Control Controls all copier functio n s both directly or

through other control board s.

AC Drive Provides ac power to the exposure lamp and

fusing lamps.

CB High Voltage Supply

Operation Panel Controls the LED mat rix, and monitors the key

Noise Filter (220 ~ 240 V machines only)

Duplex Control (Duplex machines only)

Liqui d Cr ystal Display (A156 machines only)

LCT Interface (LCT machines only)

Toner Bottle Drive Rotates the toner bottle to supply toner to the

Upper Tray Lift (A153 machines only)

Lower Tray Lift (A153/A156 machines only)

LCT Lift (LCT machines only)

Optics Cooling Fan 2 (A153/A156 machines only)

Exhaust Fan 2 (A153/A156 machines only)

Scanner Drive Drives the 1st and 2nd scanners (dc stepper

Duplex Feed (Duplex machines only)

End Fence Jogger (Duplex machines only)

Supplies high voltage to the drum charge roller and development roller.

matrix. Removes electrical noise.

Controls the operation of the duplex tray.

Controls the guidance display and displ a ys guidance for machine operation.

Interfaces the LCT control signal between the main board and the LCT.

toner supply unit. Raises the bottom plate in the upper paper tray.

Raises the bottom plate in the lower paper tray.

Lifts up and lowers the LCT bottom plate.

Removes heat from the optics unit.

Removes the heat from around the fusing unit.

motor).

Drives the feed roller and moves the bottom plate up and down.

Drives the end fence jogger to square the paper stack.

FT5535/4527/4522 2-8 FSM

Symbol

Rev. 7/95

M16 60

Index

No.

Description Note

Side Fence Jogger (Duplex machines only)

Drives the side fence jogger to square the paper stack.

Sensors

S1 27

S2 31

S3 51

By-pass Feed Paper Width

By-pass Feed Paper End

Upper Tray Paper End (Non-duplex machines

Informs the CPU what width paper is in the by-pass feed table.

Informs the CPU that there is no paper in the by-pass tray.

Informs the CPU when the upper paper tray runs out of paper.

only) Upper Relay Detects the leading edge of paper from the

S4 107

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.

Lower Relay Detects the leading edge of paper from the

S7 106

lower paper tray to determine the stop tim ing of the lower paper feed clutch, and detects

misfeeds.

Detects the height of the paper stack in the lower paper tray to stop the lower tray lift motor.

S8 30

Lower Tray Upper Limit (A153/A156 machines only)

S9 100

S10 26

S11 28

LCT Lower Limit (LCT machines only)

LCT Paper End (LCT machines only)

LCT Upper Limit (LCT machines only)

Sends a signal to the CPU to stop lowering the LCT bottom plat e.

Informs the CPU when the LCT run s out of paper.

Sends a signal to the CPU to stop lifting the LCT bottom plat e.

Registration Detects the leading edge of the copy paper to

S12 28

determine the st op timing of the paper feed clutch, and detects misfeeds.

S13 50

S14 53

S15 39

S16 20

S17 15

S18 24

S19 21

Image Density (ID)

Toner Density (TD)

Lens Horizontal HP I nfor ms the CPU that the len s is at the

Lens Vertical HP Infor ms the CPU that the len s is at the full-size

Scanner HP Informs the CPU when the 1st and 2nd

3rd Scanner HP Informs the CPU when the 3rd scanner is at

Original Length-2 Detects the length of the original. This is one of

Detects the density of vario u s patterns on the drum during proc ess control.

Detects the amount of toner inside the development unit.

horizontal home position.

position.

scanners are at the home po sition.

the home position.

the APS (Auto Paper Select) sensors.

S20 45 Fusing Exit Detects misfeeds.

Platen Cov er Informs the CPU whether the platen cover is up

S21 16

or down (related to APS /ARE functi on s). ARE: Auto Reduce and Enlarg e

S22 54

Toner End In structs the CPU to add toner to the toner

supply unit, and detects toner end conditions.

FSM 2-9 FT5535/4527/4522

Rev. 7/95

Symbol

S23 43

Index

No.

Description Note

Auto Response (Not used on A161/A162

Returns the operation panel display and exits from the energy saver mode.

copiers Transfer Belt ContactHPInforms the CPU of the current position of both

S24 23

the transfer belt unit and the drum charge roll er unit.

S25 13

S26 44

S27 19

S28 56

S29 57

Auto Image Density (ADS Sensor)

Original Width Detects the width of the original. This is one of

Original Length-1 Detects the length of the original. This is one of

Duplex Paper End (Duplex machines only)

Duplex Turn (Duplex machines only)

Detects the background density of each original in ADS mode.

the APS (Auto Paper Select) sen sors.

the APS (Auto Paper Select) sen sors. Detects paper in the duplex tray.

Detects the trailing edge of the copy paper to determine the jogging timing, and detects misfeeds.

S30 62

S31 59

S32 64

S33 22

Duplex Entrance (Duplex machines only)

Side Fence Jogger HP (Duplex machines only)

End Fence Jogger HP (Duplex machines only)

Original Length (Option for N.

Detects misfeeds.

Detects the home po sition of the duplex sid e fence jogger.

Detects the home po sition of the duplex en d fence jogger.

Detects original lengt h f or 11" x 15" paper.

American models)

Switches

SW1 33

SW2 36

By-pass Feed Table Detects whether the by-pass feed table is open

or closed.

Upper Tray (Non-duplex machines

Detects whether the upper paper tray is in place or not.

only)

SW3 35

SW4 104

SW5 25

Lower Tray Detects whether the lower paper tray is in

place or not.

Tray Down (LCT machines only)

Upper Tray Paper Size (Non-duplex machines

Sends a signal to the CPU to lower the LCT bottom plate.

Determine s what size of paper is in the upper paper tray.

only)

SW6 34

SW7 32

Lower Tray Paper Size Determin e s what size of paper is in the lower

paper tray.

Vertical Guide Set (Non-LCT machines

Detects whether the vertical guide is open or not.

only)

SW8 105

SW9 103

LCT Cover-1 (LCT machines only)

LCT Cover-2 (LCT machines only)

Detects whether the LCT cover is open or not.

Cuts the dc power line of the LCT lift motor.

SW10 42 Main Supplies power to the copier. SW11 41

SW12 48

Front Cover Safety Detects whether the front door is open and via

relays cuts the ac power.

Exit Cover Safety

Detects whether the exit cover is open or not.

(A157/A160 machines only)

FT5535/4527/4522 2-10 FSM

Symbol

Index

No.

Description Note

Magnet ic Clu tch e s

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 Clutc h)

Controls the touch and release movement of both the transfer belt unit and the drum charge roller unit.

CL4 73 Registration Dri ves the registration rollers. CL5 74

By-pass Feed Starts paper feed from the by-p ass feed table

or LCT.

CL6 76 Relay Drives the relay rollers.

Starts paper feed f rom the upper paper tray.

CL7 84

Upper Paper Feed (Non-duplex machines only)

CL8 85

Lower Paper Feed Starts paper feed from the lower paper tray.

Solenoids

Picks paper up from the by-pass feed table. When paper is fed from the LCT, this solenoid assists SOL3.

SOL1 75

LCT machines: LCT/By-Pass Pick-up Solenoid Non-LCT machines: By-pass Pick-up Solenoid

SOL2 91

SOL3 98

SOL4 80

SOL5 82

Junction Gate (Duplex machines only)

LCT Pick-up (LCT machines only)

Upper Tray Pick-up (A153 machines only)

Lower Tray Pick-up (A153/A156 machines

Moves the juncti on gate to dir ect copi e s to the duplex tray or to the paper exit.

Picks up paper from the LCT.

Controls the up/down movement of the pick-up roller in the upper paper tray.

Controls the up/down movement of the pick-up roller in the lower paper tray.

only)

SOL6 81

Upper Tray Separation (A153 machines only)

Controls the up-down movement of the separation roller in the upper paper tray feed station.

Controls the up-down movement of the separation roller in the lower paper tray feed station.

SOL7 83

Lower Tray Separation (A153/A156 machines only)

Lamps

L1 17

L2 65

Exposure Applies high intensity light to the origi nal for

exposure.

Main Fusing P rov id e s heat to the central area of the hot

roll e r .

L3 66 Secondary Fusing Provides heat to both ends of the hot roller.

Pre-transfer Reduces the charge remaining on the drum

L4 4

surface before transfer.

Quenching Neutralizes any charge remaining on the drum

L5 5

surface after cleaning.

Erase After exposure, this eliminates the charge on

L6 2

area s of the drum that will not be used for the image.

FSM 2-11 FT5535/4527/4522

Symbol

Heaters

H1 38

H2 46

H3 37

Thermistors

TH1 69

TH2 70 TH3 47 Optics Moni tor s the temper ature of the optics cavity. TH4 49

Thermofuses

TF1 68

TF2 67

TF3 18

Counters

CO1 40 Total Keeps track of the total number of copies made. CO2 N/A

Others

CB1 9

CC1 10 Choke Coil Removes high frequency current.

TR1 7

Index

No.

Description Note

Drum Turns on when the main switch is off to keep

the temperature around the drum charge rolle r at a certai n lev el . Also prevents moist ure f rom formi ng around the drum .

Optics Anti-condensation (option )

Lower Tr a y (option)

Main Fusing Monitors the temperature at the central area of

Secondary Fu sing Monitor s the tempe r ature at the ends of the hot

Drum Charge Monitors the temperature of the drum char g e

Main Fusing Provides back-up overheat protection in the

Secondary Fusing Provides back- up over heat protec tion in the

Exposure Lamp Opens the exposure lamp circuit if the 1st

Key (option )

Circuit Breaker (220 ~ 240V machines only)

Transformer (220 ~ 240V machines only)

Turns on when the main switch is off to prevent moisture from forming on the optics.

Turns on when the main switch is off to keep paper dry in the lower paper tray.

the hot roller.

roller.

fusing unit.

scanner overheats.

Used for control of authorized use. The copier will not operate until it is installed.

Provides back-up high current protection for electrical components.

Steps down the wall voltage to 100 Vac.

FT5535/4527/4522 2-12 FSM

5. DRIVE LAYOUT

5.1 ALL MODELS

1. Drum Drive Pulley

2. Drum Charge Roller Drive Gear

3. Transfer Belt Contact Clutch Gear

4. Scanner Drive Motor

5. Scanner Drive Pulley

6. Transfer Belt Drive Gear

7. Fusing Unit Drive Gear

8. Main Motor

9. Main Pulley

10. Registrati o n Clut ch Ge ar

11. By-pass Feed Clut ch Gear

12. Development Drive Clutch Gear

13. Toner Supply Clu t ch Gear

FSM 2-13 FT5535/4527/4522

Rev. 7/95

5.2 A153/A156

1. Upper Paper Feed Clutch Gear (A153/A15 5 only)

2. Lower Paper Feed Clutch Gear

3. Relay Clutch Gear

5.3 A157/A160/A161/A162

1. Upper Paper Feed Clutch Gear (A157and A161 only)

2. Lower Paper Feed Clutch Gear

3. Relay Clutch Gear

FT5535/4527/4522 2-14 FSM

SECTION 3

INSTALLATION

Rev. 7/95

1. INSTALLATION REQUIREMENTS

1.1 ENVIRONMENT

1. Temperature Range: 10°C to 30°C (50°F to 86°F)

2. Humidity Range: 15% to 90% RH

3. Ambient Illu mina ti on: Less than 1,500 lux (do not expose to direct sunlig ht.)

4. Ventilation: Room air should turn over at least 3 m3/hr/person

5. Ambient Dust: Less than 0.10 mg/m3 (2.7 x 10-6 oz/yd3)

6. If the place of installation is air-conditioned or heated, place the machine:

a) where it will not be subjected to sudden temperature changes. b) where it will not be directly exposed to cool air from an air conditioner. c) where it will not be directly exposed to heat from a heater .

7. Do not place the machine where it will be exposed to corrosive gases.

8. Do not install the machine at any location over 2,000 m (6,500 feet) above

sea level.

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 ba ck: Within 5 mm (0.2") of level

2. Right to left: Within 5 mm (0.2") of level

FSM 3-1 FT5535/4527/4522

1.3 MINIMUM SPACE REQUIREMENTS

Place the copier near the power source, providing clearance as shown:

More than 10 cm/4.0"

More than 39 cm/15. 4"

NOTE: *1. In machines without an LCT, the di stan ce bet ween the wall

and the edge of the by-pass feed table must be more than 28.5 cm/11.3".

REAR

(See Note *2)

Your machine

FRONT

More than 70 cm/27.6"

More than

28.5 cm/11.3" (See Note *1)

*2. Copier only + Receiving Tray

103.0 c m/40.6 " (with L CT: 125. 8 cm/49. 6")

Copier + A554 Sorter/Stapler

103.2 c m/40.7 " (with L CT: 126. 0 cm/49. 7")

Copier + A555 Sorter/Stapler

100.1 c m/39.5 " (with L CT: 122. 9 cm/48. 4")

Copier + A556 Sorter

96.6 cm/38.1" (with LCT: 119.4 cm/47.1")

FT5535/4527/4522 3-2 FSM

1.4 POWER REQUIREMENTS

CAUTION

A. Be sure to ground the machine. B. Make sure the plug is firmly inserted in the outlet. C. Avoid m ulti-wiring.

1. Input voltage level:

120V/60Hz: More than 12 A (for North America) 220V~240V/50Hz: More than 7 A (for Europe) 220V/50Hz: 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.

FSM 3-3 FT5535/4527/4522

2. COPIER INSTALLATION

2.1 ACCESSORY CHECK

Check the quantity and condition of the accessories in the box against the following list:

Description Qty

1. Paper Size Decal.....................................................................................1

2. Symbol Explanation Decal (except for the A156 copier).........................1

3. Optional Zoom Function Decal................................................................1

4. Optional Margin Adjustment Function Decal...........................................1

5. Combine Originals Explanation Decal (exce pt for the A156 copi er ).......1

6. Receiving Tray.........................................................................................1

7. Operating Instructions (except for –27 machines)............... .... ................1

8. User Survey Card (–17 machine s only)....... ........................ .... .... ............1

9. New Equipment Condition Report...........................................................1

FT5535/4527/4522 3-4 FSM

2.2 COPIER INSTALLATION PROCEDURE

- A153/A155/A156 copiers -

[C]

Rev. 7/95

[A]

[B]

- A157/A159/A160 copiers -

[C]

[A]

[B]

[E]

[D]

- A155/A156/A159/A160 copiers -

[E]

[D]

CAUTION

Never lift the machine by holding the LCT, or the LCT will break.

NOTE:(1) Keep the shipping retainers after installing the machine. They will be

reused if the machine is moved to another location in the future.

(2) Proper rei nsta l lati on of the shippi n g retai ners is required in order to

avoid any transport d a mage. It is most impor tant to put back the scanner lock pin when transporting this copier. If not, skewed image may result.

1. Remove the scanner lock pin [A] and red tag [B] as shown.

2. A155/A156/A159/A160 copiers onl y: Remove the strips of tape and the

sheet of paper [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).

FSM 3-5 FT5535/4527/4522

- A156 copier -

[H]

[F]

[I]

[D]

[C]

[G] [B]

[F]

- A160 copier -

[F]

[I]

[B]

[E]

[C]

[A]

[B]

[D]

[G] [B]

[F]

[E]

4. A156/A160 copiers only:

1) Pull out the duplex tray [A] and remove the strips of tape [B].

2) Remove the guide roller stopp er [C] and a sheet of paper [D].

3) Open the upper duplex guide plate [E] and remove the strips of tape [F].

4) Open the low er dupl e x guide plate [G], and re move the styrofoam support [H] and the sheet of paper [I].

5) Install the duplex tray in the copier.

[A]

FT5535/4527/4522 3-6 FSM

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