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

14

22

201918

171613

12

– A156 copier –

4
3

2

1

38
37

36
35
34

33
32

31

30

29

5

28 27 26

25

6

7

24 23

1098

11

15

21

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

14

22

20191817161312

– A160/A162 copier –

4
3

2

1

38
37

36

35
34
33
32

31

30

5

6

7

1098

11

15

21

28

27

26

25

24

23

29

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.

roller.

fusing unit.

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

3

4

6

5.1 ALL MODELS

13

12

11

10

1

9

8

2

5

7

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

3

2

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

3

2

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]

[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

- A153/A155/A156 copiers -

[C]

[A]

[B]

- A157/A159/A160 copiers -

[C]

[B]

[B]

[A]

[F]

[G]

[E]

[D]

5. Open the front cover and swing out the toner bottle hold er [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].

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.

FSM 3-7 FT5535/4527/4522

Rev. 7/95

[D]

[B]

[A]

[C]

[H]

[F]

[E]

[G]

11. Remove the knob screw [A].

12. á Swing out the bottle holder [B] and í pull down the lock lever [C].

ó Then slide out the bottle holder assembly [D] and ú swing out the bottle

holder assembly [D].

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 3-8 FSM

[B]

[A]

[F]

[E]

[C]

[D]

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 develope r [C] int o the devel o p ment unit . Then
rotate the outer gear [D] as shown to distribute the developer evenly. T hen
pour in all the remaining developer and rotate the gear again.

NOTE: T o prevent the developer from spilling, do not rotate the gears in the

other dire cti on.

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).

FSM 3-9 FT5535/4527/4522

Rev. 7/95

[C]

[D]

[A]

[B]

19. Swing in the bottle holder assembly [A] so that the toner bottle holder [B] and
the slide rail [C] are aligned straig ht.

IMPORTANT: Do not swing the bottle holder into the machine before doing
step 20.

20. Slide the bottle holder a ssembly in as described below:

1) Slide the bottle holder assembly into its lock position while pressing down

the bottle holder lock lever [D].

2) When the bottle holder assembly reaches its lock position, push up the

bottle holder lock lever so that the knob screw holes are aligned.

3) Secure the bottle holder lock lever with the knob screw.

CAUTION

Do not swing the bottle holde r assembly al l the way into its origi nal
position in the machine wit ho ut sliding a nd locki ng it into posit io n exact l y
as described above. Otherwise, the assembly will be damaged.

21. Install a toner bottle by fo llowing the instructions placed on the reverse side of
the front cover.

22. Swing in the toner bottl e hold er to its original posi tion and close the front
cover.

23. Plug in the copier and turn on t he main switch.

FT5535/4527/4522 3-10 FSM

24. Enter SP mode as follows:

1) Press the "Clear Modes" key.

2) Enter "107" using the numeric keys.

3) Hold down the "Clear/Stop" key for more than 3 seconds.
NOTE: When SP mode is selected, "1" blinks in the 3rd digit of the copy

counter, the Auto I mage Density indi cat or star ts blin ki ng, and the
reduce/enlarge indicator turns off.

25. Perform the "TD sensor initial setting" SP mode as fol lows:

1) Enter "2" and press the "Enter" key.

Rev. 7/95

2) Enter "214" and press the "Enter" key.

3) Press the "Start" key.
NOTE: The machine will auto matically stop when TD sensor initia l setti ng is

completed. (It takes abou t 2.5 minute s.)

26. Perform the "Compulsory toner supply" SP mode as follows:

1) Press the "Clear Modes" key twice.

2) Enter "2" and press the "Enter" key.

3) Enter "207" and press the "Enter" key.

4) Press the "Start" key.
NOTE: The machine will auto matically stop when c o mpulsor y toner suppl y is

completed. (It takes abou t 30 seconds.)

5) Compulsory toner supply must be performed twice in order to supply

enough toner to the toner hopper, so press the "Start" key again.

- A156 copier only -

Select the proper language for the guidance display as follows:

1) Press the "Clear Modes" key twice.

2) Enter "5" in the 3rd digit of the copy counter and pre ss the "Enter" key.

3) Enter "910" and press the "Enter" key.

4) Enter the nu mber for the desir ed langu age in th e three -dig i t indi cator 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.

FSM 3-11 FT5535/4527/4522

[B]

[A]

[D]

[C]

[E]

On the paper tray

On the duplex tray

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: T he side and rear fences should be properly positioned.

29. Select the appropr i ate pape r size for the paper trays in the main body by
sliding the paper size slider into the correct position (see section 2.3.2 "Paper
size selection for the copier paper trays" for details).

30. When a paper tray unit is installed: Enter the proper paper size for each
paper tray by following the proced ure shown in section 2.3, "Pape r Size
Selection" and in "Servi ce Table s - SP5-019 : Paper Size Setti ng ".

31. Load paper into the paper trays and the copy tray.

32. Attach the appropr iate paper si ze decals [A] to the paper trays.
Also (A156/A160 copiers only), attach the duplex decal to the duplex tray.

NOTE: Paper size decals are used also for the paper tray unit. Save the

remaining decals for use with the paper tray unit.

33. Install the optional platen cover [B] as follows if necessary:

1) Install 2 stud screws [C] on the top cover as shown.

2) Position the platen cover bracket [D] on the stud screws and slide it to the

left.

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 pro cedure.)

35. Check the copy quality and machine operation.

FT5535/4527/4522 3-12 FSM

2.3 PAPER SIZE SELECTION

By-pass Feed

Copier

Paper Tray Unit

LCT

2.3.1 Paper Feed Station Definition

A153 and A157 copiers

By-pass Feed

A155 and A159 copiers

1st tray
2nd tray

3rd tray
4th tray
5th tray*

A156 and A160 copiers

By-pass Feed

1st tray

2nd tray
3rd tray

4th tray*

LCT

Copier

Paper Tray Unit

Copier

Paper Tray Unit

1st tray
2nd tray
3rd tray
4th tray
5th tray*

The diagrams on this page
show how the paper feed
stations are numbered in the
various models.

NOTE: *A549 paper tray unit only

FSM 3-13 FT5535/4527/4522

2.3.2 Paper Size Selection for Copier Paper Trays

[A]

For the 1st tray and 2nd tray for A153, A155, A157, and A1 59 copier s, and the
1st tray for A156 and A160 copiers, slide the paper size slider [A] to the paper
size indicati on that matches the paper size in the tra y. T he following paper sizes
can be selected with the paper size slider .

A4/A3 Version LT/DLT Version

A3 (lengthwise) 11" x 17"
B4 (lengthwise) 8
A4 (lengthwise) 81/2" x 11"
A4 (sideways) 11" x 8
B5 (lengthwise) A4 (lengthwise)
B5 (sideways) A4 (sideways)
A5 (sideways) 8
8

1/2" x 11" 11" x 15"

11" x 8
11" x 17" F4 (8
F4 (8

1/2" 10" x 14"

1/2" x 13") (lengthwise) 8" x 10"

1/2" X 14"

1/2"

1/2" x 51/2"

1/2" x 13") (lengthwise)

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 FSM

2.3.3 Pa per Size Select io n for the Paper T ray Unit, LCT , and By-pass Feed

For the paper tray unit, LCT and by-pass feed, select the paper size with SP
mode (SP5-019) using the following procedure.

1. Enter SP mode as follows;

1) Press the "Clear Modes" key.

2) Enter "107" with the numeric keys.

3) Hold down the "Clear/Stop" key for more than 3 seconds.
NOTE: When SP mode is selected, "1" blinks in the 3rd digit of the copy

counter, the Auto I mage Density indi cat or star ts blin ki ng, and the
reduce/enlarge indicator turns off.

2. Enter SP5-019 as follows

1) Enter "5" and press the "Enter" key.

2) Enter "019" and press the "Enter" key.

3. Press the or key until the requi re d 3rd level progr am number is
selected.

3rd level (001~008

can be selected with

keys.
SP5-019-001 ——————
SP5-019-002 ————
SP5-019-003
SP5-019-004

SP5-019-005

SP5-019-006
SP5-019-007

SP5-019-008 — —

A153/A157 copiers A155/A159 copiers A156/A160 copiers

Paper

Tray

Indicator

3
4

5

1

Paper

Size

Selection

3rd Tray
4th Tray

5th Tray
By-pass

Feed

SPECIAL*

Paper

Tray

Indicator

3
4

5

T
1

Paper

the and

Size

Selection

3rd Tray
4th Tray

5th Tray
By-pass

Feed

LCT

*SPECIAL — —

Paper

Tray

Indicator

2
3
4

T

1

Paper

Size

Selection

2nd Tray

3rd Tray
4th Tray
By-pass

Feed

LCT

SPECIAL*

Example: In an A155 copier, to select the paper size for the LCT, select 3rd level
program 007.

NOTE: The 3rd level program number is blinking in the 1st digi t of the cop y

counter.
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 2.3.4 and "Service Tables - SP5-019: Paper Size
Setting" for how to select from a wider range of paper sizes for the 1st tray.

FSM 3-15 FT5535/4527/4522

4. Select the required SP setting with the numeric keys (see Service Tables ­Paper Size Settings), then press the "Enter" key.

NOTE: If you input the wrong setti ng by mistake, you can cancel it by

pressing the "Clear/Stop" key before pressing the "Enter " key.

5. Leave SP mode by pressing the "Clear Modes" key three times.

2.3.4 Special Paper Size Selection for the 1st Tray

For the 1st tray, a wider range of paper sizes can be selected using SP5-019-007
for A153, A156, A157 and A160 copiers, or SP5-019- 008 for A155 and A159
copier s.

NOTE: The definition of the 1st tray differs with the type of copier. See section

2.3.1 "Paper Feed Station Definition".

If a special paper size is selected, the machine ignores the pape r 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 FSM

2.4 SORTER ADAPTER INSTALLATION

(OPTION FOR A157, A159, AND A160 COPIERS ONLY)

2.4.1 Accessory Check

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

Description Qty

1. Installation Procedure..............................................................................1

2. Sorter Adapter Front Cover .....................................................................1

3. Clip...........................................................................................................3

4. Philips Pan Head Screw M4 x 6 .......... .... ................................................4

FSM 3-17 FT5535/4527/4522

2.4.2 Installation Procedure

[E]

[A]

[B]

[C]

[G]

[F]

[D]

1. Remove the cover plate [A] (2 screws).

2. Remove the three plastic caps [B] from the copier left cover with nippers.

3. Install the sorter adapter [C] (4 tapping screws) in the paper exit section of
the copier.

4. Attach the sorter adap ter 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 synchr onized with the rotation
of the fusing unit knob [G].

FT5535/4527/4522 3-18 FSM

2.5 TRAY HEATER INSTALLATION (OPTION)

[H]

Rev. 7/95

[A]

[E]

[K]

[B]

[D]

[J]

[C]

[F]

[G]

[I]

[L]

[M]
[J]

NOTE: The optio nal tray heater keeps copy paper dry. In humid environments,

copy paper may crease as it comes out of the fusing unit. The heater is
available as a service part. (See the parts catalog.)

CAUTION
Unplug the copier power cord before starting the following procedure.

If the 20 bin sorter stapler (A554) has been already installed, do step 1.

1. Remove the 20-bin sorter stapler and the sort er stapl e r mounti ng fra me fro m
the copier. (See "20-BIN SORTER STAPLER INSTALLATION
PROCEDURE".)

2. A153, A155, A157, and A159 copie rs: R e move the 1st and 2nd paper trays.

3. A156 and A160 copiers: Remove the duplex unit and the 1st paper tray.

FSM 3-19 FT5535/4527/4522

Rev. 7/95

4. Remove the rear cover. (See "Replacement and Adjustment - Inner and
Outer Covers".)

5. Pull out the carrying handles [A].

6. Before installing the heat er, bind the heater harness [B] with i nsul ating tape
[C] as shown to prevent the heater harness from being damaged by the edge
of the copier main frame.

7. Pass the connector [D] through the opening [E] in the copier main frame.

8. Mount the heater [F] on the bottom of the copier main fra me (2 screws).

9. Pass the two projection s [G] throug h the opening [H] in the copier main
frame, then mount the heater cover [I] on the bottom of the copier main frame
(1 screw).

CAUTION

The heater cover is necessary, because the surface of the heater
becomes very hot.

10. Insert the clamp [J] into the rear frame, and join the connectors [K].

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 functi on .

FT5535/4527/4522 3-20 FSM

2.6 OPTICS ANTI-CONDENSATION HEATER (OPTION)

[E]

[B]

[G]

[A]

[F]

Rev. 7/95

[H]

[C]

[D]

NOTE: The optics anti - cond ensation heater keeps water from condensing on the

copier’ s mirrors.
Such condensation occurs at cold tempe rature s with high humidity, and
causes the first few copies of the day to be dark, or even black.
The heater is availabl e as a service par t. (See the part s catalog.)

CAUTION

Unplug the copier power cord before starting the following procedure.

1. Remove the exposure glass. (See "Replacement and Adjustme nt - Exposure
Glass Removal".)

2. Remove the rear cover. (See "Replacement and Adjustment - Outer Cover
Removal".)

3. Insert the two clamps [A] as shown.

4. Mount the anti-conde nsation heater [B] (2 screws).

5. Pass the connector [C] through the opening [D].

6. Clamp the harness [E] to the two clamps [A].

FSM 3-21 FT5535/4527/4522

7. Connect the red two-pin connector [F] at the rear of the copier to the heate r’s
connector [C] (red).

8. Place the harness [G] under the opti cal rail [H] as shown.

9. Make sure that the scanner drive belt and mirrors do not touch the heater
harnes s while they are functi onin g. Also, make sure that the heater har ness
does not interfere with the light path to the ADS sensor board.

NOTE: Tell the customer that even when the copie r main s witch is tur ned off,

the copier power cord should be plugged in. Otherwise, the optics
anti-condensation heater will not function.

FT5535/4527/4522 3-22 FSM

2.7 ORIGINAL LENGTH SENSOR FOR APS (OPTION ONLY FOR

THE LT/DLT VERSION)

[C]

[B]

[A]

NOTE: To detect 11" x 15" size paper by APS in platen mode, an optional

original length sensor is required. The sensor is available as a service
part. (See the parts catalog.)

CAUTION

!

Unplug the copier power cord before starting the following procedure.

[E]

[D]

1. Remove the exposure glass. (See "Replacement and Adjustme nt - Exposure
Glass Removal".)

2. Remove the lens housing cover. (See "Replacement and Adjustment ­Scanner Drive Belt Replacement".)

3. Pull out the light yellow connector [A] from under the optical rail.

4. Connect the light yellow connector [A] to the connector [B] of the optional
sensor [C].

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 setti ng . (Se e "Service Tabl e s ­Service Program Mode".)

FSM 3-23 FT5535/4527/4522

Rev. 7/95

2.8 ADS SENSOR (OPTION)

[B]

[C]
[F]

[A]

[D]

[E]

[D]

– A153, A155, and A156 copie rs onl y –

NOTE: For originals written on some types of red paper, dirty background may

occur in ADS mode. For customers who mainly use such types of red
paper originals, an optional ADS sensor which has a different sensitivity
for red originals is availa ble as a service part. (See t he part s catalog.)

CAUTION

Unplug the copier power cord before starting the following procedure.

1. A153, A155, and A156 copiers only: Remove the top cover. (See
"Replaceme nt and Adjustmen t - Outer Cover Removal".)

2. Remove the rear cover. (See "Replacement and Adjustment - Outer Cover
Removal".)

3. A153, A155, and A156 copiers only: Remove the optics cooling fan duct [A]
(2 tapping screws).

4. Remove the former ADS sensor board [B] (2 tapping screws and 1
connector) .

5. Mount the optional ADS sensor board [C] (2 tapping screws) and connect the
connectors [D] of the ADS sensor board to the adapter harness [E].

6. Clamp the harness [E] to the clamp [F] as shown.

7. Perfor m the ADS sensor initial setting with SP4-201. (See "Service Tables ­Service Program Mode".)

NOTE: A153, A155, and A156 copiers only: When r e mounti ng the opti cs cool i ng

fan duct [A], be sure not to catch the sensor harness.

FT5535/4527/4522 3-24 FSM

2.9 KEY COUNTER HOLDER (OPTION)

[D]

[B]

[F]

[C]

[E]

Rev. 7/95

[A]

CAUTION

Unplug the copier power cord before starting the following procedure.

1. Remove the front right cover [A]. (See "Replacement and Adjustment - Outer
Cover Removal".)

2. Remove the cap [B] with nippers.

3. Pass the four-pin connect or [C] of the key counter hol de r [D] throu gh the
opening [E] and couple it with the key counter connector [F].

4. Mount the key counter holder [D] (2 screws).

5. Reinstall all the covers and check the key counter’s operat ion.

6. Make sure that SP mode 5-401 is set to 0, then switch the power off and cut
JP2 on the main board.

FSM 3-25 FT5535/4527/4522

2.10 BRAND DECAL APPLICATION INSTRUCTIONS (-10 AND -22

COPIERS ONLY)

[B]

A153, A155, and A156 Copiers

[A] [A]

[C]

[B]

A157, A159, and A160 Copiers

[C]

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 FSM

SECTION 4

SERVICE T ABLES

1. SERVI CE REMARKS

1.1 HANDLING THE DRUM

The organic photoconductor (OPC) drum is comparative ly more sensitive to light
and ammonia gas than a selenium drum.

1. Never expose the drum to direct sunlight.

2. Never touch the drum surface with bare hands. When the drum surface is
touched with finge rs o r becomes dirty, wipe it with a dry cloth or clean it with
wet cotton. Wipe with a dry cloth afte r cleani ng with wet cotton .

3. Never use alcohol to clean the drum; al coho l dissol ve s the drum surface.

4. Store the drum in a cool, dry place away from heat.

5. Take care not to scratch the drum as the photoconductive layer is thin and is
easily damaged.

6. Never expose the drum to corrosive gases such as ammonia gas.

7. Always keep the dru m in its protective sheet when it is out of the copier.
Doing so avoids e xposin g the drum to bright light or direct sunlig ht. This will
protect the drum from light fatigue.

8. Apply setting powder to the entire surface of the drum before installing a new
drum.

9. Process control data initial setti n g (see section 3.1, "Practi cal SP Mode Use
Tables - Replacement and Cleaning") must be performed when a new drum
is installed.

FSM 4-1 FT5535/4527/4522

1.2 DRUM UNIT

1. Make sure that the drum unit is set in position and the drum stay is secured
with a screw when the main s witch is tur ned on. If the dr u m unit is loose, poor
contact of the drum connectors may cause electrical noise, resulting in
unexpected malfunctions (RAM data may change in the worst case).

2. Insert a clean sheet of paper between the drum and the drum charge roller
and also cover the OPC dru m with paper when you leave the dr u m unit out of
the copier more than 30 minutes. Doing so prevents the drum charge roller
from sticking to the drum. If the drum charge roller sticks to the dru m, the
chemical component of the drum charge roller affects the surface of OPC
drum.

1.3 DRUM CHARGE ROLLER

1. Do not touch the drum charge roller with bare hands. Oil stains may cause
black bands on copies due to excessive drum charge.

2. Do not adhere toner or setting powder dust to the drum charge roller. Toner
stains or setting power may cause white spots or white bands on copies due
to insufficient drum charge.

3. Prevent the dru m charge rolle r fro m being exposed to dusty air. Dust on the
drum charge roller may cause white spots on copies due to insufficient drum
charge.

4. Never use alcohol or water to clea n the drum charge roller. Alcohol or water
corrode the surface of the drum charge roller. Wipe with a dry cloth or a
Dupont Sontara DY-12 cloth - P/N A1539004.

5. Reduce the drum charge roller cleaning inter vals with SP2-901 as follo ws for
users who mainly make high volume copy runs continuously.

SP2-901 settin g Cleaning interval

0 ..................... Every 1000 copies for 10 seconds [default]

1 ..................... Every 500 copies for 10 seconds

2 ..................... Every 200 copies for 10 seconds

3 ..................... Every 100 copies for 10 seconds

6. Plug in the copier pow er cord even when the copie r main s witch is tur ned off.
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 dru m charge effici e ncy from being low for the first copy after the p o wer is
switched on.

FT5535/4527/4522 4-2 FSM

1.4 OPTICS

1. When installing the exposur e glass, make sure that the mark on the edge of
the glass faces up. This makes sure that the correct side faces up; this side
has a smoother surface and gene rat es less static electricity. Thi s is especi all y
important when the ARDF is installed.

2. When moving the 1st or 2nd scanners, always hold them at the center. Move
them slowly, carefully, and gently. Abrupt movement may cause the belt to
slip into the wrong position on the scanner drive pulleys.

3. Do not bend or crease the exposure lamp flat cable.

4. Do not touch the following parts with bare hands:
a) Reflectors

b) Exposure lamp
c) Mirrors and lens
d) ADS and VL patterns under the left scale bracke t

5. To clean the mirror s and len s, use only a clea n soft clot h dampened with
alc oho l or water.

6. The mirror surface with the reflecti ve coat in g must face the light path . The
spring plates must contact the reverse side of the mirror (th e side witho ut t he
reflective coating).

7. If you ever adjust the exposure la mp voltage with SP4-001, be sure to
perform auto ADS gain adjustment (SP4-201) and forced VL detection
(SP3-105) imme di ate ly after wards. This is because ADS gain data and VREF
data will be cleared if SP4-001 is performed.

1.5 ERASE LAMP

1. A narrower lead edge era s e 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.

FSM 4-3 FT5535/4527/4522

1.6 DEVELOPMENT UNIT

1. Be careful not to nick or scratch the development roller sleeves.

2. Place the development unit on a sheet of paper after removing it from the
copier. This prevents any small metal objects (staples, clips, E-rings, etc.)
fro m being attracted to the develop men t rol ler and getting inside the uni t.

3. Clean the drive gears after removing the used devel op er.

4. Never load different types of developer or toner into the development unit.
Doing so will cause poor copy quality and toner scattering inside the copier.

5. TD sensor initial setting (S P2 -21 4) is necessary w hen ne w devel op er is
loaded.
Do not perform the TD sensor i niti al setti ng with used developer .
Do not make any copy before TD sensor initial setting.

6. When removing the development unit, push it to the right to preve nt the OPC
drum from being scratched by part of the development unit.

7. The doctor gap and the development roller posi tion must not be adjusted in
the field as they are precisely adjusted at the factory using special tools. Do
not loosen any screws except for those needed when removing the toner
supply unit.

8. Before pulling out the development unit, disconnect the connector and
release the development unit lock lever.

9. When putting the development unit back in the copier, do not forget to
reconnect the connector.

1.7 TRANSFER BELT UNIT

1. Do not touch the transfer belt with bare hands.

2. When servicing the transfer belt cleaning unit, be careful not to damage the
edge of the cleaning blade.

3. Apply setting po wder to the transfer belt when install in g a new tran sfer belt
cleaning blade.

4. Dispose of the used toner insid e the coll e cti on tank at every pre ventive
maintenance. 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 4-4 FSM

1.8 CLEANING SECTION IN THE DRUM UNIT

1. When servicing the cleaning section, be careful not to damage the edge of
the cleaning blade.

2. Apply setting po wder to the sur face of the drum when in stalling a new
cleaning blade. Otherwise, the cleaning blade catches the drum, and both the
cleaning blade and the drum will be damaged.

1.9 ERASE LAMP/PTL/QUENCHING LAMP

1. Place a sheet of paper over the transfer belt un it when removing the erase
lamp, the pre-tr ansfer lamp (PTL), or the quenching la mp. Doing so prevent s
these lamps fro m damaging the transfer belt if they fall down by mistake.

1.10 PAPER FEED

1. Do not touch the pick-up, feed, separation rollers, or the friction pads with
bare hands.

2. The side fences and the rear fence of the paper trays should be posi tio ned
correctly in alig n ment with the actua l paper si ze. Other wi se, pape r misfeeds
may occur.

3. When using by-pass fee d while pla ci ng the original directly on the exposur e
glass, be sure to lower the platen cover or document feeder before pressing
the Start key. For the first copy using by-pass fe ed, the copi er scans full si ze.
If the platen cover is opened, a completely black image is developed on the
drum outside the copy paper size. This black image is transferred not to th e
copy paper but to the transfer belt. The toner transferred to the tran sfer belt
cannot be cleaned off completely by the cleaning blade. This may cause the
back of the next sheet of copy paper to be dirty.

4. When using by-pass feed, stop pushi n g the sheets o f copy paper at the
moment that the paper end indicator turns off. If you do not do so, all the
sheets of paper get under the feed roller, causing a jam.

5. A157, A159, and A160 only: For users who mainly use B size paper, change
the paper feed roller position to the B size paper position when paper jams or
non-feeds occur . (Se e Replacement and Adjustment - Section 6.5 Paper
Feed Roller Repla c e ment for A157/A15 9/A160.) This remark also appl i e s to
the A553 paper tray unit.

FSM 4-5 FT5535/4527/4522

6. Avoid storing paper in humid areas.
At high temperature and high humidity, or at low temperature and low
humidit y, store pape r in a plasti c bag. This i s especi ally im por tant when a
sorter stapler is installed.

7. Load the paper in the paper trays, LCT, and by-pass feed table the correct
way up as indicated on the copy paper package.
If heavy curl occurs with a paper type which has no such indication on the
package, try turni ng the paper stack over. Change the paper if the heavy curl
cannot be corrected in spite of this. This is especially important when a sorter
stapler is installed.

NOTE: Proper paper loading is as follows;

1) For the paper trays of the copi er and the pape r tray unit, the paper
must be copy side down.

2) For the by-pass feed table and the LCT, the paper must be copy
side up.

8. Do not leave paper or originals on top of the LCT. Any paper left there may
be fed into the copier and damaged.

1.11 FUSING UNIT

1. Be careful not to damage the edges of the hot roller strippers or their tension
springs.

2. Do not touch the fusing lamps with bare hands.

3. Make sure that the fusing lamps are positioned correctly and that they do not
touch the inner surface of the hot roller.

1.12 OTHERS

1. Never touch the surface of the RAM back up battery on the main board with
screwdrivers or other metallic objects.
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 4-6 FSM

2. SERVICE PROGRAM MODE

2.1 SERVICE PROGRAM MODE OPERATION

The service program (SP) mode is used to check electrical data, change modes,
and adjust settings.

2.1.1 Service Program Mode Access Procedure

How to enter the SP mode
Press the following keys in sequence.

→ → → →
NOTE: 1. The above procedur e must be finished within 20 seconds.

2. Hold the final key for more than 3 seconds .

3. When SP mode is selected , "1" blinks in the 3rd dig it of the copy
counter, the 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 procedu re must be finishe d within 20 seconds.

FSM 4-7 FT5535/4527/4522

How to select the program number

Program numbers are composed of two or three levels.
–– ––

1st Level
Program Number

2nd Level
Program Number

3rd Level
Program Number

To input the required prog r a m numbe r, select each program level in seque nce.

1. Select the 1st level and 2nd level program numbers at the numeric keys.
Then press the key.

2. If there are third level programs in this SP mode: Select the 3rd level
program number by pressing the and keys. The 3rd level
program number is displayed in the copy counter. Then press the

key.
If there are no third level programs in this SP mode: Do not press the

, , or keys at this time.

Note: If you need to return to one level befor e, pre ss the key.

3. Input the required settin g as explain ed in the following section.

2.1.2 Changing the Value of an SP Mode

1. Enter the SP mode.

2. Select the required program mode as explained above.

3. The current setting will be displayed in the reduce/e nlar ge indicato r.

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 4-8 FSM

2.2 MEMORY RESET PROCEDURES

Before starting a memory reset procedure, be sure to remember the following:
For SP3-123, SP7-804, SP7-808, SP7- 810 , and SP7-811, be sure to check again

whether you really wish to use this SP mode before you press the
If the key is pressed after entering one of these modes,

the memory will be reset.
For example, to enter SP Mode 7- 804

→ → 8 0 4 → Check the SP Number again →

7

2.2.1 Resetting Counters

To reset a counter, use any of the following SP modes.
SP7-804, SP7-810, SP7-811: Before pressing the final key, make sure

that this is the SP mode that you really wish to use.

SP Mode Number Counte r to be Reset To Check the Coun ter

SP5-404-001 Selected User Code Counter SP5-402
SP5-404-002 All User Code Counters
SP7-804 PM Counter SP7-803
SP7-807-001 Total Service Call Counters SP7-401

SP7-402

SP7-807-002 Total Copy Paper Misfeed Counter s SP7-502

SP7-504

SP7-807-003 Total Original Misfeed Counters SP7-503

SP7-505

SP7-810 Copy Counters SP7-002

SP7-101

SP7-301
SP7-811 DF Original Counter SP7-205
SP7-816-001 Tot al sheets of paper fed from the Upper Tray

(Except for A156 and A160 copiers)
SP7-816-002 Tot al sheets of paper fed from the Lower Tray SP7-204-002
SP7-816-003 Tot al sheets of paper fed from the 1st Tray of the

Paper Tray Unit
SP7-816-004 Tot al sheets of paper fed from the 2nd Tray of the

Paper Tray Unit
SP7-816-005 Tot al sheets of paper fed from the 3rd Tray of the

Paper Tray Unit
SP7-816-006 Tot al sheets of paper fed from the LCT SP7-204-006
SP7-816-007 Tot al sheets of paper fed from the By-pass Feed

Table
SP7-816-008 Total Duplex Paper Feeds SP7-204-008

SP7-204-001

SP7-204-003

SP7-204-004

SP7-204-005

SP7-204-007

key.

FSM 4-9 FT5535/4527/4522

1. Enter the required SP mode. (Do not press after entering this SP
mode until you are sure that you want to reset the counters.)

NOTE: Before pressing the

key, be sure to check again whether you

have selected the correct SP mode number or not.

2. Press the

key, then the selected counter will be reset.

2.2.2 Reset All Counters: SP7-808

This SP mode resets the following counters:

Counter to be Reset Counter check

Operation Time SP7-001
Total Original Scan Counter SP7-002
Copy Counters by Paper Size SP7-101
Total Sheets of Paper fed from the Paper Trays SP7-204
DF Original Counter SP7-205
Stapler Counter SP7-206
Reduction/Enlargement/Full Size Copy Counters SP7-301
Total Service Call Counter SP7-401
Individual Service Call Counters SP7-402
Total Jam Counter SP7-501
Total Copy Jam Counter SP7-502
Total Original Jam Counter SP7-503
Copy Jam Counters for Each Location SP7-504
Original Jam Counter s for Each Location SP7-505
PM Counter SP7-803

1. Enter SP7-80 8. (Do not press the key after entering this SP

mode until you are sure that you want to reset the counters.)
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 FSM

2.2.3 Drum Initialization: SP3-1 23

CAUTION: If SP3-123 is performed, the VR, VL, and T/H correction levels

and the drum rotation timer are reset. As a result, the old
drum cannot be used any more.
If the old drum is used after SP3-123 is performed, dirty
background and/or toner scattering will appear on copies
sooner or later because proper process control will not be
applied to the drum.
When installing a new drum, do the following procedure make
sure that the machine returns to its normal operating
conditio n.

1. Install a new OPC drum.

2. Clean the optics, sensors, and i nsi de the copi er if necessary.

3. Do SP 3-123 as follows.
3-1. Enter SP3-123. ( D o not pre ss t he key after entering this SP

mode until you are sure you want to initialize the drum data.)

3-2. Press the key. The drum data will be initialized.

4. Perfor m the followin g SP modes in the following ord er (see "Practi cal SP
Mode Use Tables" for details):

(1) SP3-001: ID Sensor Initial Setting
(2) SP3-112: Forced VR Detection
(3) SP4-001: Exposure Lamp Vo ltage Ad justment
(4) SP4-201: Auto ADS Gain Adjustment
(5) SP3-105: Forced VL Detection

5. Check the copy quality and the paper path and do any necessary
adjustments (see Replacement and Adj ustment - Copy Quali ty Adjustments).

FSM 4-11 FT5535/4527/4522

2.2.4 Reset All Memory (SP5-801)

CAUTION: Reset All Memory mode (SP5-801) resets all the correction

data for copy process control and all the software counters,
and returns all modes and adjustments to the default settings.

Normally, this SP mode should not be performed.
This procedure is required only when replacing the RAM
board or when the copier malfunctions due to a damaged
RAM board.

- Memory rese t procedure -

1. Enter SP5-80 1.

2. Press the key and the key at the same time.
NOTE: T o avoid resetting the memory by mistake, this mode is done

when the key and the key are pressed at the same
time.

3. Turn the main switch off and on.

only

- Recovering the machine after a memory reset -

CAUTION: If SP5-801 is performed, the drum rotation timer for process

control and the TD sensor initial setting data are reset. As a
result, the old drum and the old developer cannot be used any
more. Otherwise, dirty background and/or toner scattering will
appear on copies sooner or later because proper process
control will not be applied to the drum.
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 i nsi de the copi er if necessary.

FT5535/4527/4522 4-12 FSM

4. Refer to the "SP MODE FACTORY SETTING DATA" sheet locate d in the
upper inne r cover and ente r the data that wer e stored in the following SP
modes at the factory.

• SP1-001: Registration Adjustment

• SP2-001: Drum Charge Roller Voltage (for Copying)

• SP2-003: Drum Charge Roller Voltage (for VSP Pattern)

• SP2-101-001: Lead Edge Erase Margin

• SP4-001: E xposur e Lamp Voltage Adjust men t

• SP4-008: Vertical Magnification Adjustment

• SP4-011-008: Base Horizontal H.P. Adjustment

• SP4-101: Horizontal Magnification Adjustment

• SP4-102: Lens Error Correction

• SP4-103: Focus Adjustment

5. Perfor m the followin g SP modes in the following ord er (see "Practi cal SP
Mode Use Tables" for details):

(1) SP2-214: TD Sensor Initial Settin g
(2) SP3-123: Drum Initialization
(3) SP3-001: ID Sensor Initial Setting
(4) SP3-112: Forced VR Detection
(5) SP4-001: Exposure Lamp Vo ltage Ad justment
(6) SP4-201: Auto ADS Gain Adjustment
(7) SP3-105: Forced VL Detection

6. Check the copy quality and the paper path and do any necessary
adjustments (see Replacement and Adj ustment - Copy Quali ty Adjustments).

FSM 4-13 FT5535/4527/4522

2.3 SERVICE PROGRAM MODE TABLE

1. A "†" after the mode name means that copies can be made while in this SP
mode.

2. A "‡" after the default setting in the "Set tings" column means that the actual
factory setting for thi s is written on th e data sheet in the front cover.

3. A "°" before the mode number means that this mod e can be accessed by
sales representatives (

4. A "•" before the mode number means that this mode can be accessed by
users using a UP mode (
Cross Reference Table".

5. In the Function column, comments (extra information) are in italics.

6. In the Settings colu mn, the defau lt valu es are printed in bold letters.

7. "RDS" means Remote Diagnostic System (not available in these models)
"CSS" means Customer Support System (only available in Japan)

8. Type 1 = A153, A155, and A156 copiers
Type 2 = A157, A159, and A160 copiers

→ → →

→ ). See "UP Mode/SP Mode

).

2.3.1 Quick Reference

The following is a quick reference list of the SP Modes.

Mode No. Function

Paper Feed/Paper Transport/Fusing

1-001 Registration †

1-003-xxx Paper Feed Timing †

1-008 Misfeed Detection †
1-103 Fusing Idling †

°1-104 Fusing Temperature Control †

1-105-xxx Fusing Temperature Adjustments †

1-106 Fusing Temperature Display †
1-108 Forced Start †
1-902 Jogger Span Adju stment (Side Fence) †
1-905 Jogger Span Adju stment (End Fence) †

Around the Dr um

2-001 Drum Charge Voltage Adjustment (for copying)

2-002-xxx Drum Charge Voltage Display †

2-003 Drum Charge Volt age Adju stment (for making V

2-101-xxx Leading/Trailing Edge Erase Margin Adjustment †

SP patterns)

FT5535/4527/4522 4-14 FSM

Mode No. Function

2-201-xxx Devel opment Bias Adjustments †

2-203 Development Bias Adjustment (for making V SP patt erns)

2-206-xxx Development Bias Display †

2-207 Forced Toner Supply (shown as "Compulsory Toner Supply" on the

display)
2-208-001 Toner Supply Mode Selec tion †
2-208-002 Toner Supply Ratio (TD Sensor Supply Mode) †
2-208-003 Toner Supply Ratio (Fixed Supply Mode) †

2-214 TD Sensor Initial Setting

2-215-xxx TD Sensor Output Display †

2-220 TD Sen sor Initial Output Display †
2-222 Toner Supply Ratio

(Detect Supply Mode) †
2-301-xxx Transfer Current Adjustments †

Factory Use Only: Do not change the settings.

2-801 Developer Agitation
2-802 Drum Charge Roller Temperature †
2-812 Drum Reve r se Rotation Adjustment †
2-901 Drum Charge Roller Cleaning Interval †
2-902 Not Used

Process Control

3-001 ID Sensor Initial Setting
3-002 ID Sensor Initial Setting Display †

3-103-xxx ID Sensor Output Display †

3-105 Forced V

L Detection

3-106 Initial VLP/VLG Display †
3-107 Current V LP/VLG Display †
3-111 Current V RP/VRG Display †
3-112 Forced VR Detect i o n
3-123 Drum Initialize
3-801 Auto Process Control Mode Selection †
3-901 Free Run (Expo sure Lamp Off)
3-902 Forced Process Control

Optics

4-001 Exp osure Lamp Voltage Adj u stment †

°4-002 Expo sure Lamp Voltage Display †

4-008 Vertical Magnification Adjustment †

4-011-xxx Lens Horizontal H.P . Adju stments †

4-013 Scanner Free Run
4-101 Horizontal Magnification Adjustment †
4-102 Lens Error Correction †
4-103 Focus Adjustment †

Rev. 6/16/95

FSM 4-15 FT5535/4527/4522

Mode No. Function

4-201 Auto ADS Gain Adjustment
4-202 ADS Initial Gain Display †
4-203 ADS Actual Gain Display †
4-301 APS Sensor Function Check †
4-302 Optional APS Sensor (LT version only) †
4-303 APS A5/HLT Detection †
4-901 APS Size Priority (for F4 size) †

•

°4-902 APS 8K/16K Detection (A4 versions only) †

Operation

•

°5-001 All Indicators ON †

•

°5-002 Feed Station Priority Selection †

•

°5-003 APS Priority Selection †

•

°5-004 ADS Priority Selecti on †

•

°5-013 Counter Up/Down Selection †

•

°5-017 Maximum Copy Quantity †

(Copy Limit)

•

°5-019-xxx Paper Size Set †

•

°5-101 Auto Reset Time Setting †

•

°5-102 Auto Energy Saver Time Setting †

•

°5-103 Auto Tray Shift †

°5-104 A3/DLT Double Count †

•

°5-106 Image Density Level Correct ion (ADS Correcti on) †

•

°5-107-xxx Image Shift Margin Adju stment †

•

°5-108 Edge Erase Margin Adjustment †

•

°5-110 Center Erase Margin Adjustment †

°5-113 Coin Lock Installation †

5-115 Duplex Image Shif t (Back Side Margin) †

°5-121 T/C (Total Counter) Count Up Timing †

•

°5-305 Auto Off Time Setting †

°5-401 User Code Mode †

•

°5-402 User Code Counter Check †

•

°5-404-xxx User Code Counter Clear †

•

°5-405 User Code Number Setting †

•

°5-407-xxx User Code Number Clear †

°5-408 Number of Registered User Codes Display †
°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. 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 FSM

Mode No. Function

5-802-xxx Free Run Mode

5-803 Input Check Mode †
5-804 Output Check Mode

°5-810 SC Reset †

5-811 Used in Japan only. Do not change the factory setting.
°5-812 Telephone Number Input † (A156 copier only)
°5-816 Used in Japan only. Do not change the factory setting.

5-817 Used in Japan only. Do not change the factory setting.
°5-905 APS A4/LT Sideways Priority †

•

°5-906 Manual Staple Re set Time Setting †

•

°5-907 Cover Mode Selection †

•

°5-908 Image Shift/Erase Selection †

•

°5-909 10 key Zoom/Size Magnification †
°5-910 Guidance Language Setting (A156 copier only) †

Peripherals

•

°6-001 SADF Auto Reset Time Setting †

•

°6-002 ADF Free Size Setting †
°6-003 Auto Sort Selection †
°6-005 Blank Copy for Last Odd Original s in Duplex †

6-006-xxx DF Registration Adjustment †

6-009 DF Free Run with Paper

•

°6-010 Auto APS Select (DF) †

•

°6-011 Thick/Thin Original Mode Selec tion †
°6-101 Sorter Installation †
°6-102 Sorter Stack Limit †
°6-104 Staple Sheet Limit †

6-107 Sorter Free Run Mode

Counters

°7-001 Total Operation Time Displ ay †
°7-002 Total Original Counter Display †
°7-003 Copy Charge Counter for RDS/CSS Display †

This is for use with features that are available only in Japan. Ho wever,
it does show how many originals have been copi ed (total of DF mode +
platen mode).

°7-004 Initial Copy Counter Setting for RDS/CSS Display †

This is for use with features that are available only in Japan. Ho wever,
it does show the total number of copie s 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 †

FSM 4-17 FT5535/4527/4522

Mode No. Function

°7-206 Stapler Counter †

°7-301-xxx Total Copies by Magnification †

°7-401 Total Servi c e C all Counter †
°7-402 SC Counter by Service Call †
°7-501 Total Jam Counter † (Copies + Originals)
°7-502 Total Jams by Paper Size † (Note: This is actually the T otal Copy

Paper Jam Counter. The counter is not divided up by Paper Size)

°7-503 Total Original Jam Counter

°7-504-xxx Total Jams by Location †
°7-505-xxx Total Original Jams by Location †
°7-801-xxx Main ROM Version Display †

°7-803 PM Counter Check †
°7-804 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 FSM

2.3.2 SP Mode Ta ble

Mode No. Functio n Set tin g s

1-001 Registration † Adjusts leading edge registration. 0 ~ 32

(0.5 mm per step [range: –8.0 mm to +8.0
mm])

1-003-001

to

1-003-008

Paper Feed
Timing †

Adjusts the paper feed timing at registrati o n
for each paper feed station. Paper feed ti min g
is in proportion to the amount of paper
bending [mm] at registration.

(1 mm per step [range: –16 mm to + 16 mm])

SP Number

SP1-003-001 1st tray Duplex
SP1-003-002 2nd tray 1st tray
SP1-003-003 3rd tray 2nd tray
SP1-003-004 4th tray 3rd tray
SP1-003-005 5th tray 4th tray
SP1-003-006 By-pa ss By-pass
SP1-003-007 LCT LCT
SP1-003-008 Japan only

Without

Duplex

With

Duplex

Rev. 7/95

Default = 16 ‡

0 ~ 32

Default = 16

SP1-003-008:
Do not adjust
this setting.

1-008 Misfeed

Detection †

1-103 Fusing Idling † Selects whether fusing idling is done or not.

Switches misfeed detection on or off for test
purposes (sensor signals are ignored). Only
one copy can be made at a time, to prevent
damage to the machine.

Fusing idling lasts 2 minutes.

After selecting ON or OFF, turn the main
switch off and on.

°1-104 Fusing

Temperature
Control †

Selects the fusing lamp temperature control
mode.

After selecting the control mode, turn the main
switch off and on.

1-105-001 Fu sing

Temperature
Adjustm ent
(Main Fusing
Lamp) †

Adjusts the temperature of the main fusing
lamp, which heats the central area of the hot
roller.
The selected temperat ure is displayed in the
reduce/enlarge indicator.

(1°C per step [range: 170°C to 190°C])

0: ON

1: OFF

0: OFF

1: ON

0: On/Off
Control

1: Phase Control

170 ~ 190

Default = 180

(Type 1)

Default = 175

(Type 2)

FSM 4-19 FT5535/4527/4522

Mode No. Function Settings

1-105-002 Fu sing

Temperature
Adjustm ent for
Energy Saver
Mode †

1-105-003 Fusing

Temperature
Adjustment
(Secondary
Fusing Lamp) †

Adjusts the temperature of the main and
secondary fus ing lamps in energy saver
mode.
(SP5-102 and SP5-305 are also related to
Energy Saver Mode.)

SP Data Type 1 Type 2

0 175°C 175°C
1 160°C 150°C
2 145°C 125°C
3 130°C 100°C
4 115°C 75°C
5 95°C —

The lower the fusing temper ature i s, the
greater the energy saving ratio is and the
longer the waiting time until the copier returns
to the ready condition.

Adjusts the temperature of the secondary
fusing lamp, which heats both ends of the hot
roller.

(1°C per step [range: 160°C to 190°C])

0 ~ 5
(Type 1)
0 ~ 4
(Type 2)

Default = 0

160 ~ 190

Default = 175

1-106 Fusing

Temperature
Display †

Displays the fusing temper ature (° C) on the
surface of the central area of the hot roller, as
measured by the thermist or.

The temperature in energy saving mode
cannot be displayed, as entering SP mode
takes the machine out of this mode.

1-108 Forced Start † Selects whether f orced start i s on or off. 0: OFF

If forced start is switched on, the copier enters

1: ON

the ready condition even if the fusing
temperature has not reached the required
value yet. Use this for tests if the room
temperature is low and you do not wish to wait
for the lamps to warm up.

1-902 Jogger Span

Adjustment
(Side Fence) †

Adjusts the stop position of the jogger side
fence span of the duplex unit.

(0.5 mm per step [range: –8.0 mm to +8.0

0 ~ 32

Default = 16

mm])

A156 and A160 copiers only

1-905 Jogger Span

Adjustment
(End Fence) †

Adjusts the stop position of the jogger end
fence span of the duplex unit.

(0.5 mm per step [range: –8.0 mm to +8.0

0 ~ 32

Default = 16

mm])

A156 and A160 copiers only

FT5535/4527/4522 4-20 FSM

Mode No. Functio n Set tin g s

2-001 Drum Charge

Voltage
Adjustm ent (for
copying) †

2-002-001

to

2-002-002

Drum Charge
Voltage Display
†

2-003 Drum Charge

Voltage
Adjustm ent (for
making V

SP

pattern s) †

2-101-001

to

2-101-002

Leading/Trailing
Edge Erase
Margin
Adjustm ent †

2-201-001 Dev elopment

Bias
Adjustm ent (for
copying) †

2-201-002 Light e st ID

Level
Development
Bias
Adjustm ent †

2-20 3 Development

Bias
Adjustm ent (for
making V

SP

pattern s) †

Adjusts the voltage applied to the drum charge
roller during copying.

The adjustment factor set with this SP mode is
added to the base voltage.
(30 V per step [Range: Base voltage - 480 V
to Base voltage + 480 V]

Displays the voltage applied to the drum
charge roller.
SP2-002-001: For copying
SP2-002-002: For making V

SP patterns

The first three digits are displayed in the
reduce/enlarge indicator. The actual value is
the displayed value x (–10) V.
Just after the main switch is turned on, the
initial setting voltage is displayed.
After one or more copies, the actual applied
voltage (including the process control
corrections) is displayed.

Adjusts the voltage applied to the drum charge
roller when making V

SP patterns.

The adjustment factor set with this SP mode is
added to the base voltage.
(10 V per step [Range: Base voltage –160 V
to Base voltage + 160 V]

Adjusts the leading and trailing edge erase
margins.
SP2-101-001: Leading edge erase margin
SP2-101-002: Trailing edge erase margin

(0.5 mm per step [range: 0.0 mm to +16.0
mm])

Adjusts the development bias for copying to
make copies lighter or darker in general.

The adjustment factor set with this SP mode is
applied to the base voltage.
(20 V per step [Range: Base voltage –80 V to
Base voltage +80 V])

Adjusts the development bias for manual ID
level 7.

The adjustment factor set with this SP mode is
applied to the base voltage when ID level 7 is
selected.

Adjusts the development bias for making V

SP

patterns

The adjustment factor set with this SP mode is
added to the base voltage.
(20 V per step [Range: Base voltage - 10 V to
Base voltage + 80 V]

0 - 32

Default: 16
(0V) ‡

0 - 32

Default: 16
(0V) ‡

0 - 32

Default = 16

‡ (only 2-101­001 is on the
data sheet)

1 - 9
Default = 5 (0V)

1: Darkest
9: Lightest

1: –40 V

2: ±0 V
3: –80 V
4: –120 V

1 - 10

Default = 6 (0V)

FSM 4-21 FT5535/4527/4522

Mode No. Function Settings

2-206-001

to

2-206-002

2-207 Forced Toner

2-208-001 Toner Suppl y

2-208-002 Toner Suppl y

2-208-003 Toner Suppl y

Development
Bias Display †

Supply (shown
as "Compulsory
Toner Supply"
on the display)

Mode Selection
†

Ratio
(TD Sensor
Supply Mode) †

Ratio
(Fixed Supply
Mode) †

Displays the development bias.
SP2-206-001: Development bias used

for copying.

SP2-206-002: Development bias used

for making V
patterns.

SP sensor

The first two digits are displayed in the
reduce/enlarge indicator. The actual value is:
displayed value x (–10) V. All process control
corrections are included in the displayed value.

Forces the toner bottle to supply toner to the
toner supply unit for 30 seconds.

This mode is started by pressing the "Start"
key and stops automatically after about 30
seconds. Press the"Clear Modes" key to
interrupt if necessary. This SP mode must be
performed twice when installing the machine
and when installing a new toner supply unit.

Selects the toner supply mode.
In many cases, the machine will change the
toner supply mode automati call y if either the
TD or ID sensor become unrel iabl e. H o wever,
sometimes it does not.
If the TD sensor fails, you can select fixed
supply mode as a temporary measure.
If the ID sensor fails, you can select TD
sensor supply mode.
After repairing the machi ne, check whether
the toner supply mode has gone back to the
detect supply mode.

Selects the toner supply ratio for TD sensor
supply mode.
For example, if the user normally makes
copies of originals that are about 7% black,
select the 7% setting for best result s.

Selects the toner supply ratio for Fixed Supply
Mode.
For example, if the user normally makes
copies of originals that are about 6% black,
select the 6% setting for best result s.

1: TD sensor
supply mode
2: Fixed supply
mode

3: Detect
supply mode

1: 7%

2: 15 %

3: 30%
4: 60%

1: 2%
2: 4%

3: 6%

4: 11%

FT5535/4527/4522 4-22 FSM

Mode No. Functio n Set tin g s

2-214 TD Sensor

Initial Setting

Performs the TD sensor initial setting. This SP
mode controls the voltage applied to the TD
sensor to make the TD sensor output 2.5 ± 0.1
V.
After using SP2-214, check SP2-220 to see if
the sensor is working correctly .

This mode is started by pressing the Start key
and stops automatically after about 2.5
minutes. Use this mode only after adding new
developer.

2-215-001

to

TD Sensor
Output Display †

2-215-002

2-220 TD Sensor

Initial Output
Display †

2-222 Toner Supply

Ratio
(Detect Supply
Mode) †

2-301-001

to

Transfer Current Adjustments †
Factory U se Only: Do not change the setting s.

2-301-002

Displays the TD sensor output voltage.
SP2-215-001: V

T = Current TD sensor

output

SP2-215-002: V

TREF = Reference TD

sensor output

Displays the TD sensor initial setting output
(after doing SP2-214).

Normally, 2.5 ± 0.1 V is displayed.
[Range: 0 V to 5.0 V]
If it is not, the sensor may be defective.

Selects the toner supply ratio for detect supply
mode.
For example, if the user normally makes
copies of originals that are about 7% black,
select the 7% setting for best result s.

1: 7%

2: 15 %

3: 30%
4: 60%

0 ~ 32

14 (–30 µA):
Type 1
12 (–20 µA):
Type 2

2-801 Developer

Agitation

After the Start key is pressed, the developer is
agitated. To stop, pre ss the "Clear Stop" key.

Use this SP mode if the machine has not been
used for a long time.

FSM 4-23 FT5535/4527/4522

Rev. 7/95

Mode No. Function Settings

2-802 Drum Charge

Roller

Displays the drum charge roller temperature [0
~ 60°C].

Temperature †

2-812 Drum Rever se

Rotation
Adjustm ent †

Adjusts the amount of the time for the drum
reverse rotation after each copy job.

If paper dust remains on the drum, it may get
into the recycled toner. If this is happening,
increase the reverse rotation by increasing the
value of the setting.

2-901 Drum Charge

Roller Cleanin g
Interval †

Selects the drum charge roller cleaning
interval.
Turn the copier main switch off and on after
changing the setting.

The drum charge roller is cleaned briefly at the
end of each copy job. The drum charge roller
is also cleaned for 10 seconds after the
interval selected with this SP mode.

2-902 Not Used ­3-001 ID Sensor Initial

Setting

Performs the ID sensor initial setting. I D
sensor output for the bare area of the drum
(V

SG) is adjusted to 4.0 ± 0.2 V.

To start this SP mode, press the "Start" key.

0 ~ 32

Default = 16
(about 3 mm)

0: Every 1000
copies

1: Every 500
copies
2: Every 200
copies
3: Every 100
copies

3-002 ID Sensor Initial

Setting Di spla y
†

3-103-001

to

ID Sensor
Output Display †

3-103-002

3-105 Forced VL

Detection

3-106 In itia l VLP/VLG

Display †

3-107 Current

V

LP/VLG

Display †

3-111 Current

V

RP/VRG

Display †

Displays the initial setting value of the ID
sensor.

Normally 4.0 ± 0.2 V is displayed. If the ID

±

sensor cannot be adjusted to 4.0

0.2 V, the

ID sensor or the OPC drum should be cleaned.

Displays the ID sensor outputs.
SP3-103-001: V

SP

SP3-103-002: VSG

Normally, VSP = 0.01 ~ 2.50 V, VSG = 4.0

±

0.2 V (VSP/VSG ≈ 0.1)

After the "Start" key is pressed, the initial
VLP/VLG (= VREF) is determined.

For when to use this SP mode, see "Practical
SP Mode Use Table".

Displays the initial V

LP/VLG value determined

by SP3-105.
Displays the current V

This is the value currently being used for V

LP/VLG value [%].

L

correction.

Displays the current V

This is the value currently being used for V

RP/VRG value [%]

R

correction.

FT5535/4527/4522 4-24 FSM

Mode No. Functio n Set tin g s

3-112 Forced VR

Detection

After the "Start" key is pressed, forced V
detection is done.

R

For when to use this SP mode, see "Practical
SP Mode Use Table".

3-123 Drum Initialize This resets the following data regarding the

OPC drum:

1. V

R correction level

2. V

L correction level

3. OPC counter

4. T/H correction level

This SP mode must be used only when a
new drum is in s talled. Refer to "Practical SP

Mode Use Table" for the exact timing for using
this SP mode.

3-801 Auto Process

Control Mode
Selection †

Selects whether auto process control mode is
on or off.
If the auto process control mode is switched
off , V

R correction, VL correction , and the

1000-copy process control cycle will not be
performe d .

This SP mode can be used to help determine
whether a copy quality problem is caused by
process control or by the machine itself.

3-901 Free Run

(Exposure
Lamp Off)

Perform s a free run wit h the ex p o sure lamp of f.

Start the free run by pressing the "Start" key
and stop it by pressing the "Clear/Stop" key.

Be sure to perform this mode without a
development u nit, or too much toner wi ll
be consumed from th e develo per, causing
low image density.

3-902 Forced Process

Control

Performs the 1000-copy process control
cycles forcibly.
V

SG initial adjustm ent → VR detection → VL

detection → VADS (pattern) adjustment

This mode starts after the "Start " key is
pressed.

4-001 Exposure Lamp

Voltage
Adjustm ent †

Adjusts the exposure lamp voltage
(0.5 V per step [Range: 50.0 V to 75.0 V])

For 115 V machines, the actual applied
voltage = displayed value x 1.1412.

After doing this SP mode, ADS in it ial
setting (SP4-201) and forced V

L

detection

(SP3-105) must al so be don e.

See "Replacement and Adjustment - Copy
Quality Adjustments" for how to ad just.

0: OFF

1: ON

50.0 ~ 75.0 V

Default = 63 V ‡

FSM 4-25 FT5535/4527/4522

Rev. 7/95

Mode No. Function Settings

°4-002 Exposure Lamp

Voltage Display
†

4-00 8 Vertical

Magnificat ion
Adjustm ent †

4-011-001

to

4-011-009

Lens Horizontal
H.P.
Adjustm ent †

Displays the current exposure lamp voltage.
(0.5 V per step [Range: 50.0 V to 85.0 V])

For 115 V machines, the actual applied
voltage = displayed value x 1.1412.

Adjusts the magnification in the paper trav e l
direction .
(0.1% per step [Range: –1.6% to +1.6%])
See "Replacement and Adju stment - Copy
Quality Adju stments" for ho w to adjust.

Adjusts the le n s horizontal home position for
each paper feed station.
(0.2 mm per step [Range: –3.2 mm to +3.2
mm])

SP Number

4-011-001 1st tray Duplex
4-011-002 2nd tray 1st tray
4-011-003 3rd tray 2nd tray
4-011-004 4th tray 3rd tray
4-011-005 5th tray 4th tray
4-011-006 By-pass By-pass
4-011-007 LCT LCT
4-011-008 Base Adjustment
4-011-009 ADF ADF

Without

Duplex

With

Duplex

50.0 ~ 85.0 V

0 ~ 32

Default = 16 ‡

0 ~ 32

Default = 16
‡ (only 4-011­008 is on the
data sheet)

4-013 Scanner Free

Run

4-101 Horizontal

Magnification
Adjustm ent †

SP4-011-008 changes the home position for
all paper feed stations at the same time. It is
mainly used for making factory adjustments. If
it is shifted by a certain amount, all other
SP4-011 adjustments move by the same
amount.
See "Replacement and Adjustment - Copy
Quality Adjustments" , and "Side-to-side
Registration" in the ARDF manual for details
on how to adjust.

Starts the scanner free run.

Start the scanner free run by pressing the
"Start" key, and stop it by pressing
"Clear/Stop".

Adjusts the magnification perpendicular to the
direction of paper trav el .
(0.2% per step [Range: –1.6% to +1.6%])
See "Replacement and Adju stment - Copy
Quality Adju stments" for ho w to adjust.

0 ~ 32

Default =16 ‡

FT5535/4527/4522 4-26 FSM

Mode No. Functio n Set tin g s

4-102 Lens Error

Correction †

4-103 Focus

Adjustm ent †

4-201 Auto ADS Gain

Adjustm ent

4-202 ADS Initial Gain

Display †

4-203 ADS Actual

Gain Display †

4-301 APS Sensor

Function Check
†

Adjusts the lens position to correct for
magnification in enlarge/reduce mode.
(0.1% per step [Range: –0.8% to +0.8%])

Adjusts the 3rd mirror position to correct the
fine focus.
(0.05 mm per step [Range: left 3.75 mm to
right 3.75 mm])
See "Replacement and Adju stment - Copy
Quality Adju stments" for ho w to adjust.

Adjusts the ADS gain automatically to make
the sensor output 2.7 ± 0.1 V.

Close the platen cover to prevent external light
from reaching the ADS sensor. Then press the
"Start" key to make the adjustment.

Displays the ADS sensor output adjusted by
SP4-201.

Displays the current ADS sensor output.

Check the APS sensors.
If they are working correctly, the following
value is displayed in the reduce/enlarge
indicator.

LT Version

A4

Version

ADF/Platen

Without

optional

APS

With

optional

APS

000

Open

ADF/Platen

95 127 95

Closed

0 ~ 16

Default: 8 (0 %) ‡

0 ~ 150

Default = 75 ‡

LT version:
0 or 95
(without
optional APS)
0 or 127
(with optional
APS)
A4 version:
0 or 95

4-302 Optional APS

Sensor †

(LT version
only)

4-303 APS A5/HLT

Detection †

Set this to 1 when installing the optional APS
sensor.

This SP mode is effective only for the LT
version. In the A4 version, even if "1" is
selected, the setting is ignored.

Selects whether A5/HLT forced detec tion is
done or not.

If "YES" is selected, paper si zes that cannot
be detected by the APS sensors are regarded
as A5 lengthwise (for A4 models) or 5
8

1/2

" (for LT models).

1/2

" x

If "NO" is selected, "Check Paper Size" will be
displayed.

0: Not installed

1: Installed

0: NO

1: YES

FSM 4-27 FT5535/4527/4522

Rev. 7/95

Mode No. Function Settings

4-901 APS Size

Priority (for F4
size) †

•

°4-902 APS 8K/16K

Detection †

(A4 versions
only)

•

°5-001 All Indicator s

ON †

•

°5-002 Feed Station

Priority
Selection †

Selects which copy paper size the machi ne
selects when the APS sensors detect F4
lengthwise (8

1/2" x 13").

Selects whether the machine c a n select
8K/16K copy paper based on APS sensor

0: 8

1/2" x 13"

1: 8" x 13"
2: 8

1/4" x 13"

0: NO

1: YES
readings.
If "YES" is selected, 8K/16K copy paper is
selected under the follo wing condition s:

Size detected

by APS

B4 lengthwise

A4 lengthwise

B5 sideways

Selected copy paper

size

8K lengthwise

(267 mm x 390 mm)

16K lengthwise

(267 mm x 195 mm)

16K sideways

(115 mm x 267 mm)

Turns on all indicators on the operation panel.

Selects the paper feed station priority. 1 ~ 6: Non duplex

Setting

Non duplex

machines

Duplex

machine s
1 1st Tray 1st Tray
2 2nd Tray 2nd Tray
3 3rd Tray 3rd Tray
4 4th Tray 4th Tray
5 5th Tray LCT

machines

1 ~ 5: Duplex

machines

Default = 1
(without LCT)
Default = LCT (5
or 6)

(with LCT)

6 LCT —

•

°5-003 APS Priority

Selection †

•

°5-004 ADS Priority

Selection †

•

°5-013 Counter

Up/Down
Selection †

•

°5-017 Maximum Copy

Quantity †
(Copy Limit)

•

°5-019-001

Paper Size Set†Sets the paper size for each paper tray and

to

5-019-008

Specifies whether the copier de faults to APS
or manual mode when the main s witch is
turned on, auto reset, or mode cleared.

Specifies whether the copier de faults to ADS
or manual ID mode when the mai n s witch is
turned on, auto reset, or mode cleared.

Selects whether the counter counts up or
down.

Limits the maximum copy quanti ty that can be
entered.

feed station.

1: APS

0: Manual
Also see
SP6-010.

1: ADS

0: Manual

1: Up

2: Down

1 ~ 999

Default = 999

For how to input
the settings, see
section 2.7.

FT5535/4527/4522 4-28 FSM

⇒

⇒

Mode No. Function Settings

•

°5-101 Auto Reset

Time Setting †

Inputs the auto reset time after the copier
enters standby, or disables auto reset.

(1 second per step [Range: 1 ~ 999])
If "0" is selected, auto reset is disabled.

•

°5-102 Auto Energy

Saver Time

Sets the time that the machine enters energy
saver mode after entering the ready condition,

Setting †

•

°5-103 Auto Tray Shift†Selects whether auto tray shift is on or off. 0: OFF

°5-104 A3/DLT Double

Count †

Specifies whether the counter is doubled for
A3/DLT paper.

If "ON" is selected, the total counter and the
current user code counter counts up twice
when A3/DLT copy paper is used.

•

°5-105-002 Fuser temp † Fuser temperature can be selected in energy

saver mode

Rev. 1/26/96

0 ~ 999

Default = 60

1 ~ 120 minutes
(1minute per step)
(Default: 15
minutes)

1: ON
0: OFF

1: ON

SP

Type 1 Type 2

Data

0

175° C 175° C

1

160° C 150° C

2

145° C 125° C

3

130° C 100° C

4

115° C 75° C

5

95° C

Default
2: (145°C) :FT5035/5535
2: (125°C) :FT4027/4527
3: (100°C) :FT4022/4522

-

•

°5-106 Image Density

Level
Correction
(ADS
Correction) †

•

°5-107-001

to

5-107-002

•

°5-108 Edge Erase

Image Shift
Margin
Adjustment †

Margin
Adjustment †

Selects the image density level correction. 0: Dark

The development bias voltage correction in
ADS mode depends on this setting (see "ADS

1: Normal

2: Light

Correction" in the Process Control section for
details).

This controls the margin width adjustment for
the Left and Right margin adjustment keys.
SP5-107-001: Left
SP5-107-002: Right

SP5-908 must be at 2 for this to have any
effect; this changes the function of the Erase

A4 version

0 ~ 15

Default = 5

LT version

0 ~ 0.60

Default = 0.20

key to a Margin Adjustment key.
(A4 version: 1 mm per step [Range: 0 mm to
15 mm],
LT version: 0.01" per step [Range: 0" to

0.60"])

Adjusts the edge erase margin width in erase
edge mode.

SP5-908 must be at 1 for this to have any
effect. A strip of the selected width will be
erased around the edges of the copy image.

A4 version

1: 5 mm

2: 10 mm

LT version

1: 0.20"

2: 0.40"

FSM 4-29 FT5535/4527/4522

Rev. 1/26/96

Mode No. Function Settings

•

°5-110 Center Erase

Margin
Adjustment †

Adjusts the center erase margin width in erase
center mode.

SP5-908 must be at 1 for this to have any
effect.
(A4 version: 1 mm per step [Range: 8 mm

to 25 mm],

LT version: 0.01" per step [Range: 0.32" ~

1.00"])

A4 version

8 ~ 25

Default = 20

LT version

0.32 ~ 1.00

Default = 0.80

⇒

°5-113 Coin Lock

Installation †

5-115 Duplex Image

Shift †
(Back Side
Margin)

°5-121 T/C (Total

Counter) Count
Up Timing †

•

°5-305 Auto Off Time

Setting †

°5-401 User Code

Mode †

Specifies whether coin lock is installed or not
(only for Japanese versions).

Specifies whether duplex image shift (back
side margin) is used or not.

If "YES" is selected, a 5 mm margin is made
on the right of the reverse side of copies when
making two-sided copies from one-sided
originals.
If the image shift mode has been selected with
SP5-908 and if the user uses image shift
mode, this SP mode has no effect.

Determines whether the total counter counts
up at paper feed or at paper exit.

Sets the time to go into the auto off condition. 1 ~ 120 minutes

After JP2 on the main board is cut, either key
counter mode or user code mode can be
selected with this SP mode.

0: Not installed

1: Installed

0: NO

1: YES

0: Feed

1: Exit

(1minute per step)
(Default: 60
minutes)

0: Key Counter

1: User Code

•

°5-402 User Code

Counter Check
†

FT5535/4527/4522 4-30 FSM

Displays the user code counters.

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 and keys to check each
user code counter.

Mode No. Functio n Set tin g s

•

°5-404-001

to

5-404-002

User Code
Counter Clear †

Resets the user code counters.
SP5-404-001: Resets the counter for the
user code that is now displayed in the
reduce/enlarge indicator.
SP5-404-002: Resets all the UC counters.

To reset the counter(s), press .

SP5-404-001: The user code must be input at
the numeric keys before it can be displayed
and the counter reset, so you must know what
user codes are in use. Take a look with
SP5-405.

•

°5-405 User Code

Number Sett in g
†

Use this mode to input the user code numbers
(max. 3 digits).

Up to 50 user codes can be set. To input a
code, enter it at the numeric keys then press
the R/# key. Then you can input another. To
check the user codes input so far, use the

and keys. The user codes input

will be displayed in reduce/enlarge counter.

•

°5-407-001

to

5-407-002

User Code
Number Clear †

Deletes user code numbers.
SP5-404-001: Deletes individual user
code numbers. Enter the required user code

at the numeric keys, then press the
key. (To see which user codes are being
used, use SP5-405.)
SP5-407-002: Deletes all the user code
numbers.

°5-408 Number of

Registered

Displays the number of registered user codes

in the reduce/enlarge indicat or.
User Codes
Display †

°5-501-001 PM Interval

Setting †

°5-501-002 PM Interval

Setting (PM
Alarm Mode
Setting) †

Sets the PM interval.

(1000 copies per step [Range: 1 to 999])

Specifies whether PM alarm mode i s on or off. 0: OFF

If PM alarm mode is on, the manual ID

level/ADS indicator and copy counter blink

when the PM counter reaches the PM interval.

5-504 RDS/CSS Alarm Level for Paper Jam (Paper Jam Alarm Level Setting) †

Used in Japan only. Do not change the factory setting.

Rev. 7/95

1 ~ 999
(max. 50 codes)

1 ~ 999

120: Type 1
100: Type 2

1: ON

5-505 RDS/CSS Alarm Level for SC (Servi ce Call Alar m Level Setting) †

Used in Japan only. Do not change the factory setting.

°5-507 RDS/CSS Alarm Level for Supplie s (Supply Alarm Mode Setting) †

Used in Japan only. Do not change the factory setting.

FSM 4-31 FT5535/4527/4522

Rev. 7/95

Mode No. Function Settings

5-801 Memory All

Clear †

Resets all the correction data for process

control and all software counters, and returns

all modes and adjustments to the defaul t

setting s.

See Service Table s - section 2.2.4 for h o w to

perform this SP mode.

Normally, this SP mode should not be

performed.

This SP mode is required only when replacing

the RAM board, or when the copier

malfunctions due to a damaged RAM board.

5-802-001

to

5-802-002

Free Run Mode Performs the free run

SP5-802-001: Conti nuous free run

SP5-802-002: One time free run

Before starting, close the platen or ARDF.

Press the "Start" key to start the free run.

Press the "Clear/Stop" key to stop the free run.

5-803 Input Check

Mode †

5-804 Output Check

Mode

Displays the data received from sensors and

switches.

Turns on the electrical components

individually for test purposes.

°5-810 SC Reset † Resets any service call condition that was

caused by a level A error (see the

Troubleshooting section).

After doing SP5-810, turn the copier mai n

switch off and on.

5-811 Machine Seri al No. Input †

For use with feature s that are available in Japan only

For details, see
Service Tables
section 2.5.

For details, see
Service Tables ­section 2.6.

°5-812 Telephone

Number Input †

(A156 copier
only)

Use this to input the telephone nu mber of the

service representative (this is displayed when

a service call condition occurs.) Maximum 16

digits. Press the "

•" key to input a pause (–).

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 FSM

Mode No. Function Settings

°5-905 APS A4/LT

Sideways
Priority †

•

°5-906 Manual Staple

Reset Time
Setting †

•

°5-907 Cover Mode

Selection †

Specifies whether the machine selects LT
sideways paper if the original is A4.
If "ON" is selected, LT sideways copy paper is
selected automatically when the APS sensors
detect an A4 sideways original. This feature
does not work in reverse (A4 sideways paper
is not selected for an LT sideways original).

Sets the manual staple reset time.
(1 second per step [Range: 1 to 999])

After the end of a copy job in sort mode,
manual staple mode is reset automatically
when the manual staple reset time has passed.

Use to select whether to have a front cover or
both front and back covers added to copies in
cover mode.
Copy paper for the cover pages should be
placed on the by-pass feed table.

Rev. 1/26/96

0: OFF

1: ON

1 ~ 999

Default = 20 s

1: Front/Back

2: Front

⇒

•

°5-908 Image

Shift/Erase

Selects whether to have an image shift mode
or an image erase mode.

Selection †

•

°5-909 10 key

Zoom/Size

Selects whether to have a 10 key zoom
function or a size magnification function.

Magnification †

°5-910 Guidance

Language

Selects the language used on the operation
panel display (except for SP mode guidance).

Setting †

(A156 copier
only)

•

°5-911 Copy Mode Copy mode selected when machine is turned

on.

•

°6-001 SADF Auto

Reset Time

Sets the auto reset time for SADF mode.
(1 second per step [range: 1 to 99 seconds])

Setting †

1: Erase mode

2: Shift mode

1: Size
magnification

2: 10 key zoom
function

1: English
2: French
3: German
4: Italian
5: Spanish
6: Swedish
7: Portuguese
8: Danish
9: Norwegian
10: Finnish
11: Dutch

1: Duplex copy
mode (default)
2: Single side
copy mode

1 ~ 99

Default = 5

FSM 4-33 FT5535/4527/4522

Mode No. Function Settings

•

°6-002 ADF Free Size

Setting †

Specifies whether ADF free size sett ing is o n

or off.

Switch this on if the user makes copies of

originals that contain paper of different sizes.

Advise users that skew may occur if the

papers are of different widths, so for example,

put the A4 pages sideways if accompanied by

A3 pages.

If this feature is switched on, the copying

speed will be reduced.

0: OFF

1: ON

°6-003 Auto Sort

Selection †

°6-005 Blank Copy for

Last Odd
Originals in
Duplex †

6-006-001

to

DF Registration
Adjustm ent †

6-006-002

6-009 DF Free Run

with Paper

Specifies whether auto sort mode is on or off.

In auto sort mode, when two or more original s

are placed on the ADF, sort mode is selected

if the copy quantity is between 2 and 20.

Specifies whether a blank copy is added af ter

the last page for an odd number of original s in

duplex mode.

In SADF or platen mode, the last page always

stays in the duplex unit, regardless of this

setting.

Adjusts the registrat ion of the document

feeder.

SP6-006-001: One-sided original

SP6-006-002: Two-sided original

(0.3 mm per step [Range: –4.8 mm to +4.8

mm])

See "Vertical Registration" in the ARDF

manual for details on how to use these

adjustments.

To start the DF free run, put some sheets of

paper on the ARDF then press the "Start" key.

Stop the free run by pressing "Clear/Stop".

0: OFF

1: ON

0: Not added
(the last page
stays in the
duplex unit)

1: Added

0 ~ 32

Default = 16

This is a general free run controlled from the

copier. For more detailed free run modes, see

the manual for the DF.

•

°6-010 Auto APS

Select (DF) †

Selects whether auto APS mode is used with

the DF or not.

0: OFF

1: ON

If "ON" is selected, APS mode is selected

automatically when an original is placed on

the DF. This SP mode is in effect only when

the APS priority (SP5-003) is set to Manual.

•

°6-011 Thick/Thin

Original Mod e
Selection †

Selects the original feed type for the DF.

In thin mode, originals will not be pushed back

against the left scale.

0: Thick mode

1: Thin mode

FT5535/4527/4522 4-34 FSM

Mode No. Functio n Set tin g s

°6-101 Sorter

Installat ion †

Use this to specify which sorter is installed. 0: No sorter

After setting this SP mode, the copier main

switch must be turned off and on.

For the A554 and A555 sorter stapler, the

setting does not have to be changed (keep it

at 0).

1: A557 sorter
2: A556 sorter
3: Not used
4: A568 sorter
adapter only

°6-102 Sorter Stack

Limit †

°6-104 Staple Sheet

Limit †

Select which sorter stack limit to u se. 0: OFF

1: ON

OFF: Sorting and stacking can be done until the sorter’ tray

cannot take any more paper. Then copying stops and the R

indicator lights.

ON: Sorting and stacking can be done until the following limit is

reached. Then copying stops and the R indicator lights.

A554 Sorter/Stapler

Sort Mode: 30 (A4/LT), 15 (B4/LG, A3/DLT )

Stack Mode: 15 (A4/LT, B4/LG , A3/DLT )

A555 Sorter/Stapler

Sort Mode: 30 (A4/LT), 25 (B4/LG, A3/DLT )

Stack Mode: 25 (A4/LT), 20 (B4/LG , A3/DLT )

A556 Sorter

Sort Mode: 30 (A4/LT), 15 (B4/LG) , 10 (A3/DLT )

Stack Mode: 30 (A4/LT), 10 (B4/LG , A3/DLT )

A557 Sorter

Sort or Stack Mode: 20 (A4/LT), 15 (B4/LG ), 10 (A3/DLT)

Select whether there is a stapling limit for the

sorter stapler.

0: OFF

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 not be done

even if the user selects stapling mode.

A554 Sorter/Stapler: 20 (A4 - B5/LT)

, 10 (A3 - B4 / DLT - LG)

A555 Sorter/Stapler: 20 (A4 - B5/LT, A3 - B4 / DLT - LG)

6-107 Sorter Free

Run Mode

Start the sorter free run by pressing the "Start "

key. Stop it by pressing the "Clear/Stop" key.

This is a general free run controlled from the

copier. For more detailed free run modes, see

the sorter manuals.

°7-001 Total Operation

Time Display †

Displays the total operation time (hours).

The first three digits are displayed in the

reduce/enlarge indicator. Hold down the "

•

"

key to display the last three digits.

FSM 4-35 FT5535/4527/4522

Mode No. Function Settings

°7-002 Total Original

Counter Display

Displays the total number of scanned ori gi nals

(DF + platen).
†

The first three digits are displayed in the

reduce/enlarge indicator. Hold down the "

key to display the last three digits.

°7-003 Copy Charge Counter for RDS/CSS Display †

This is for use with features that are availabl e only in Japan. However, it does show
how many originals have been copied (total of DF mode + platen mode).
The 4th ~ 6th digits are displayed in the reduce/enlarge indi cat or. Hold down the "0"
key to display the 7th digit, and hold d o wn the "

•" key to display the 3rd ~ 1st digits.

°7-004 Initial Copy Counter Setting for RDS/CSS Display †

This is for use with features that are availabl e only in Japan. However, it does show
the total number of copi es that have been made.
The 4th ~ 6th digits are displayed in the reduce/enlarge indi cat or. Hold down the "0"
key to display the 7th digit, and hold d o wn the "

•" key to display the 3rd ~ 1st digits.

•

"

°7-101-001

to

7-101-005

Total Copie s by
Paper Size †

Displays the total num ber of copi es by paper

size.

SP Number A4 Version LT Version
SP7-101-001 A3 DLT
SP7-101-002 B4 LG
SP7-101-003 A4 LT
SP7-101-004 A5 HLT
SP7-101-005 Others Others

The first three digits are displayed in the
reduce/enlarge indicator. Hold down the "
key to display the last three digits.

°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 FSM

Mode No. Functio n Set tin g s

°7-204-001

to

7-204-008

Feed Unit
Counter †

Displays the total num ber of copies fed from
each feed unit.

SP Number

Without

Duplex

With

Duplex
SP7-204-001 1st tray —
SP7-204-002 2nd tray 1st tray
SP7-204-003 3rd tray 2nd tray
SP7-204-004 4th tray 3rd tray
SP7-204-005 5th tray 4th tray
SP7-204-006 LCT LCT
SP7-204-007 By-pa ss By-pass
SP7-204-008 — Duplex

The first three digits are displayed in the
reduce/enlarge indicator. Hold down the "
key to display the last three digits.

°7-205 DF Counter † Displays the total num ber of ori ginals fed by

the DF.

The first three digits are displayed in the
reduce/enlarge indicator. Hold down the "
key to display the last three digits.

°7-206 Stapler Counter†Displays the total num ber of st apling runs.

•

"

•

"

°7-301-001

to

Total Copie s by
Magnificat ion †

7-301-003

°7-401 Total Service

Call Counter †

°7-402 SC Counter by

Service Call †

The first three digits are displayed in the
reduce/enlarge indicator. Hold down the "

•

"

key to display the last three digits.

Displays the following counters:
7-301-001: Copies made in full size mode
7-301-002: Copies made with reduction
7-301-003: Copies made with
enlargement

The first three digits are displayed in the
reduce/enlarge indicator. Hold down the "

•

"

key to display the last three digits.

Displays the total num ber of service calls that
have occurred.

Displays the service call counter s for each
service call code.

The service call code is displayed in the copy
counter indicator, and the number of times this
SC code has occurred is di spl ayed i n
reduce/enlarge indicator.

By pressing the and keys,
another service call number and its counter
can be displayed.

FSM 4-37 FT5535/4527/4522

Mode No. Function Settings

°7-501 Total Jam

Counter †
(Copies +
Originals)

°7-502 Total Jams by

Paper Size †
(Note: This is
actually the
Total Copy
Paper Jam
Counter. The
counter is not
divided up by
Paper Size)

Displays the total num ber of copy j ams pl us
original jam s (max. 4 digits).

The first digit is displayed in the
reduce/enlarge indicator. Hold down the "

•

key to display the last three digits.

Displays the total copy paper jam counter
(max. 4 digits).

The first digit is displayed in the
reduce/enlarge indicator. Hold down the "

•

key to display the last three digits.

"

"

°7-503 Total Original

Jam Counter

°7-504-001

to

Total Jams by
Location †

7-504-006

°7-505-001

to

7-505-002

Total Original
Jams by
Location †

Displays the total ori ginal jam counter (max. 4
digits).

The first digit is displayed in the
reduce/enlarge indicator. Hold down the "

•

"

key to display the last three digits.

Displays the total copy paper jam counts by
location (max. 4 digits).

SP Number

Paper Jam Location

Symbol
SP7-504-001 Y
SP7-504-002 A
SP7-504-003 B
SP7-504-004 C
SP7-504-005 Z
SP7-504-006 R

The first one digit is displayed in the
reduce/enlarge indicator. Hold down the "

•

"

key to display the last three digits.

Displays the total ori ginal jams in the DF by
location (max. 4 digits).
SP7-505-001: Feed-in section
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 FSM

°7-801-001

to

7-801-004

Mode No. Functio n Set tin g s

Main ROM
Version Display
†

Displays the ma in ROM version.
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. The first three digits are displayed in
the reduce/enlarge indicator. Hold down the "

•

"
key to display the last three digits. The
six-digit number shows the ROM version as
follows.

Last four digits
of ROM P/No.

Suffix of ROM
P/No.

°7-803 PM Counter

Check †

Last two

digits

Suffix

Last two

digits

Suffix

00 No suffix 13 M
01A14N
02 B 16 P
03 C 17 Q
04 D 18 R
05 E 19 S
06 F 20 T
07 G 22 V
08 H 23 W
10J24X
11 K 25 Y
12 L 26 Z

Note: 09, 15, 21 do not exist because

suffixes I, O, and U are not used.

Displays the PM counter after the last PM
(max. 6 digits).

The first three digits are displayed in the
reduce/enlarge indicator; hold down the "
to display the last three digits.

•

" key

°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.

FSM 4-39 FT5535/4527/4522

Mode No. Function Settings

°7-807-001 SC Counter

Clear †

Resets the total SC counter (SP7-401) and
the individual counters f or each type of
Servi c e C all (SP7-402).

To reset the counters, press the key.

°7-807-002 Copy Jam

Counter Reset
†
(displayed a s
"SC Counter
Clear")

°7-807-003 Original Jam

Counter Reset
†
(displayed a s
"SC Counter
Clear")

°7-808 Counter All

Clear

Resets the total copy jam counter (SP7-502)
and the copy jam counters for individual
locations (SP7-504).

To reset the counters, press the key.

Resets the total original jam counter
(SP7-503) and the original jam counter s for
individual locations (SP7-505).

To reset the counters, press the key.

Resets the follo wing counters.

Counters that are reset

Operation Time SP7-001
Scanning Counter SP7-002
Copy Counter SP7-101
Total Sheets of Paper Fed

from the Paper Tray
DF Originals Counter SP7-205
Stapler Counter SP7-206
Reduction/Enlargem ent

Counter
Tot al Service Call Count er SP7-401
Each Service Call Counter SP7-402
Jam Total Counter SP7-501
Copy Paper Jam Total

Counter
Original Jam Total Counter SP7-503
Total Counter of Copy Paper

Jams for Each locat ion
Total Counter of Original

Paper Jams for Each
location

PM Counter SP7-803

Counter

check

SP7-204

SP7-301

SP7-502

SP7-504

SP7-505

After pressing the final key when
entering this SP mode, the counters will be
reset.

FT5535/4527/4522 4-40 FSM

Mode No. Functio n Set tin g s

°7-810 Copy Counter

Clear

°7-811 DF Counter

Clear

°7-816-001

to

Feed Unit
Counter Clear †

7-816-008

Resets the follo wing counters.

• Total Original Counter (SP7-002)

• Total Copies by Paper Size ( SP7-101)

• Total Copies by Magni ficat i on (SP7-301)

After pressing the final key when
entering this SP mode, the counters will be
reset.

Resets the DF counter (SP7-205).

After pressing the final key when
entering this SP mode, the counter will be
reset.

Reset one of the following counter s by
pressing the key.

SP Number

Without

Duplex

With

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 LCT LCT
SP7-816-007 By-pa ss By-pass
SP7-816-008 — Duplex

FSM 4-41 FT5535/4527/4522

2.4 UT MODE AND SP MODE CROSS REFERENCE TABLE

UT Mode SP Mo d e Functio n

1 5-019 Paper Size Set
2 5-002 Feed Station Priority Sel ection
3 5-003 APS Priority Selection
4 6-010 Auto APS Select (DF)
5 5-103 Auto Tray Shift
6 5-013 Counter Up/Down Selection
7 5-017 Maximum Copy Quantity
8 5-101 Auto Reset Time Setting

9 5-102 Auto Energy Saver Time Settin g
10 5-305 A uto Off Time Setting
11 5-004 ADS Priority Selection
12 5-106 Image Density Level Correction
13 5-907 Cover Mode Selection
14 5-908 Image Shift/Era se Selecti o n
15 5-909 10 Key Zoom / Size Magni ficat ion
16 5-107 Image Shi ft Margin Adjustment
17 5-108 Edge Erase Margin Adjustment
18 5-110 Center Erase Margin Adjustment
19 5-906 Manual Staple Reset Time Setting
20 6-001 SADF Auto Reset Time Setting
21 6-002 A DF Free Size Setting
22 6-011 Thi ck/ Thin O riginal Mode Selection
23 5-402 User Code Counter Check
24 5-404 User Code Counter Clear
25 5-405 User Code Number Setting
26 5-407 User Code Number Clear
27 5-001 A ll Indi cat o r s On
28 4-902 APS 8K/16K Det ecti on

FT5535/4527/4522 4-42 FSM

2.5 SP5-803 SENSOR/SWITCH INPUT CHECK

1. Access SP5-80 3 (ref er to section 2.1).

2. Select the required 3rd level program number using the and
keys. See the following page for a list of which 3rd level number to use for
each component.

Rev. 7/95

NOTE:

Do not press after selecting the 3rd level program number or
this SP mode will not operate.

3. If you want to check the signal during th e copy cycle, enter the n u mber of
copies in the copy counter and press the Start key.

4. The reading ("0" or "1") will be displayed in the reduce/enlarge indicator.

5. To check the reading from another sensor, switch, or signal, repeat from step

2.

3rd level

No.

1 Upper Relay Sensor Paper not detected Paper detected
2 Lower Relay Feed Sensor Paper not detected Paper detected
3 3rd Tray Paper Feed Sensor

(Paper Tray Unit)

4 4th Tray Paper Feed Sensor

(Paper Tray Unit)

5 5th Tray Paper Feed Sensor

(Paper Tray Unit)
6 Registration Sensor Paper not detected Paper detected
7 Fusing Exit Sensor Paper not detected Paper detected
8 By-pass Feed Paper Width Sensor See the Note after the end of this table.
9 By-pass Feed Paper End Sensor Paper detected Paper not detected

10 By-pass Feed Table Switch Table is closed Table is open
11 Upper Tray Paper End Sensor Paper detected Paper not detected
12 Upper Tray Upper Limit Sensor Down Up
13 Not Used – –
14 Upper Tray Switch Not set Set
15 Lower Tray Paper End Sensor Paper detected Paper not detected
16 Lower Tray Upper Limit Sensor Down Up
17 Not Used – –
18 Lower Tray Switch Not set Set
19 1st Tray Paper End Sensor

(Paper Tray Unit)

20 1st Tray Upper Limit Sensor

(Paper Tray Unit)

21 1st Tray Set Sensor

(Paper Tray Unit)

22 2nd Tray Paper End Sensor

(Paper Tray Unit)

23 2nd Tray Upper Lim it Sensor

(Paper Tray Unit)

Sensor/Sw i tch /Sig nal

01

Paper not detected Paper detected

Paper not detected Paper detected

Paper not detected Paper detected

Paper detected Paper not detected

Down Up

Not set Set

Paper detected Paper not detected

Down Up

Reading

FSM 4-43 FT5535/4527/4522

Rev. 7/95

3rd level

No.

24 2nd Tray Set Sensor

(Paper Tray Unit)

25 3rd Tray Paper End Sensor

(Paper Tray Unit)

26 3rd Tray Upper Limit Sensor

(Paper Tray Unit)

27 3rd Tray Set Sensor

(Paper Tray Unit)

28 LCT Paper End Sensor Paper detected Paper not detecte d
29 LCT Upper Lim it Sensor Off On
30 LCT L o wer Limit Sensor Off On
31 LCT Connect or Not connected Connected
32 LCT T ray D o wn Switch Off On
33 LCT Cov er S witch Cover closed Cover open
34 Original Length Sensor 1 Off On
35 Original Width Sensor 3 Off On
36 Original Width Sensor 4 Off On
37 Original Width Sensor 5 Off On
38 Original Length (Optional) Sensor Off On
39 Original Length Sensor 2 Off On
40 Scanner H.P. Sensor Off On
41 Lens horizontal H.P. Sensor Off On
42 Lens vertical H.P. Sensor Off On
43 3rd scanner H.P. Sensor Off On
44 Optics Thermistor Off On
45 Platen Cov er Close Sensor Platen cover open Platen cover closed
46 Pl aten Cover Open Sensor Platen cover closed Platen cover open
47 Vertical Guide Set Switch Vertic al guide closed Verti cal guide open
48 Paper Exit Cover S witch Paper exit cover

49 Fr ont Cover Switch Front cover closed Front cover open
50 Sorter Entrance Sensor Off On
51 Sorter Bin H.P. Sensor Off On
52 Sorter Bin Lift Sensor Off On
53 Sorter Cover Switch Cover closed Cover open
56 Proof Tray Exit Sensor (A554 Sorter

Stapler Only )

57 Bin Exit Sensor (A554)/Sorter

Entrance Sensor (A555)

58 Bin Sensor (A554/A555) Off On
59 Bin H.P. Sensor Off On
60 Bin Lift Timing - 1 Sensor (A554)/

Wheel Sensor (A555)

61 Bin Lift Timing-2 Sensor (A554 only) Off On
63 Jogger H.P. Se n sor (A554/A556) Off On
64 Grip H.P. Sensor (A554/A555) Off On
66 Stapl e H.P. (A554/A 555) Off On
67 Staple End Switch Off On
68 Stapl e Paper Sensor Off On
69 Sort er Stapl er Set SW . Front Door

SW (A554) Door Safety SW (A554)

Sensor/Sw i tch /Sig nal

01

Not set Set

Paper detected Paper not detect ed

Down Up

Not set Set

closed

Paper detected Paper not detect ed

Paper detected Paper not detect ed

Off On

Door Closed Door Open

Reading

Paper exit cover open

FT5535/4527/4522 4-44 FSM

3rd level

Rev. 7/95

No.

70 Roller Drive Timing Sensor

(A554)/Timing Sensor (A554)

73 Duplex Entrance Sensor Off On
74 Duplex Turn Sensor Off On
75 Duplex Paper End Sensor Paper detected Paper not detected
76 Upper Tray Switch Not set Set
77 Duplex Side Fence Jogger H.P.

Sensor

78 Duplex End Fence Jogger H.P.

Sensor

80 Main Motor Lock Off On
81 Fusing Uni t Set Sensor Not set Set
82 Transfer Belt Contact H.P. Sensor Off On
83 Toner End Sensor Toner remains Toner end
84 Key Counter Set Not set Set
85 Not Used – –
86 Total Counter On Off On
87 Auto R e sponse Sensor Off On
90 ADF Original Width Sensor-3 Off On
91 ADF Original Width Sensor-2 Off On
92 ADF Original Width Sensor-1 Off On
93 ADF Registration Sensor Paper not detected Paper detec ted
94 ADF Feed Out Sensor Paper not detected Paper detected
95 ADF Position Sensor ADF closed ADF open
96 ADF APS Start Sensor On Off
97 ADF Feed In Cover Open Sensor Cover closed Cover open
98 ADF Feed Out Cover Open Sen sor Cover closed Cover open

Sensor/Sw i tch /Sig nal

01

Off On

Off On

Off On

Reading

NOTE When SP5-803-008 (By-pass Feed Paper Width Sensor) is selected,

one of the following numbers will be displayed in the reduce/en larg e
indicator, depending on the by-pass feed side fence position.

A4/A3 Version

Side Fence Positi on Displ ayed Nu mber

A3 7

11" 3

B4 11
A4 (lengthwise) 9
B5 (lengthwise) 13
A5 (lengthwise) 12
B6 (lengthwise) 14

LT/DLT Version

Side Fence Positi on Displ ayed Nu mber

11" 3

1/2" 9

8

8" 13

5

1/2"14

FSM 4-45 FT5535/4527/4522

Rev. 7/95

2.6 SP5-804 ELECTRICAL COMPONENT OUTPUT CHECK

1. Access SP5-80 4 (ref er to section 2.1).

2. Select the required 3rd level program number using the and
keys. See below for a list of which 3rd level number to use for each
component.

3. Press the Start key to turn on the electrical component.

4. Press the Clear/Stop key to turn off the electrical component.

5. To turn on another electrical compone nt, rep eat from step 2.

CAUTION: The motors keep turning in this output mode regardless of

inputs from sensors. To prevent mechanical or electrical
damage, do not keep the electrical component on for a long
time.

3rd level No. Electrical Component

1 Main moto r
2 Relay clutch
3 Registration clut ch
4 Transfer belt contact clutch
5 Junction gate SOL
6 Not used
7 Sorter drive motor (A556 and A557 sorters only)
8 By-pa ss feed CL

9 By-pa ss feed pick-up SOL
10 Upper paper feed CL
11 Upper tray separation SOL
12 Upper tray pick up SOL
13 Upper tray lift motor (up)
14 Upper tray lift motor (down)
15 Lower paper feed CL
16 Lower tray separation SOL
17 Lower tray pick-up SOL
18 Lower tray lift motor (up)
19 Lower tray lift motor (down)
20 LCT pick-up SOL (LCT Equipped Units Only)
21 Not used
22 Not used
23 LCT display
24 Bin drive motor up
25 Bin drive motor down

FT5535/4527/4522 4-46 FSM

3rd level No. Electrical Component

26 Sorter stapler roller driv e motor
27 Sorter stapler turn gate SOL
28 Sorter stapler bin lift motor
29 Sorter stapler jogger motor
30 Sorter stapler grip motor
31 Sorter stapler motor
35 Exhaust fan (Left)
36 Exhaust fan (Right) 1
37 Optics cooling fan (1 or 2)
40 Exposure lamp
41 Quenching lamp, PTL
42 Toner supply CL
43 Develop ment CL
44 Toner supply bottle motor
50 ADF feed-in motor
51 ADF feed-in motor (reverse)
52 ADF belt drive motor
53 ADF bel t drive m otor (rever s e )
54 ADF feed-out motor
55 ADF inverter SOL + Entrance SOL
56 ADF display on

Rev. 7/95

FSM 4-47 FT5535/4527/4522

2.7 SP5-019 PAPER SIZE SETTING

2.7.1 Paper Size Selection for the Pape r Tray Unit, LCT, and By-pass Feed

For the paper tray unit, LCT and by-pass feed, the paper size can be selected
with SP5-019 using the following procedure.

1. Enter SP mode as follows;

1) Press the "Clear Modes" key.

2) Enter "107" with the numeric keys.

3) Hold down the "Clear/Stop" key for more than 3 seconds.
NOTE: When SP mode is selected, "1" blinks in the 3rd digit of the copy

counter, the Auto I mage Density indi cat or star ts blin ki ng, and the
reduce/enlarge indicator turns off.

2. Enter SP5-019 as follows

1) Enter "5" and press the "Enter" key.

2) Enter "019" and press the "Enter" key.

3. Press the or key until the required 3rd level program number is
selected.

3rd level (001~008
can be selected with

the and

keys.

SP5-019-001 ——————
SP5-019-002 ————
SP5-019-003
SP5-019-004

SP5-019-005
SP5-019-006

SP5-019-007
SP5-019-008 — —

Example: In an A155 copier, to select the paper size for the LCT, select 3rd level
program 007.

A153/A157 copiers A155/A159 copiers A156/A160 copiers

Paper

Tray

Indicator

3
4

5

1

Paper

Size

Selection

3rd Tray
4th Tray

5th Tray
By-pass

Feed

SPECIAL*

Paper

Tray

Indicator

3
4

5

T

1

Paper

Size

Selection

3rd Tray
4th Tray

5th Tray
By-pass

Feed

LCT

*SPECIAL — —

Paper

Tray

Indicator

2
3
4

T

1

Paper

Size

Selection

2nd Tray

3rd Tray
4th Tray
By-pass

Feed

LCT

SPECIAL*

NOTE: • The 3rd level program number is blinking in the 1st digit of the

copy counter.

• Depending on the 3rd level progr a m numbe r, the pape r 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 FSM

Rev. 7/95

4. Select the required SP setting with the numeric keys in accordance with the
following tabl e s, then press the "Enter" key.

NOTE: If you input the wrong SP setting by mistake, you can cancel it by

pressing the "Clear/Stop" key before pressing the "Enter" key.

Paper size SP settings for the paper tray unit

SP Settings A4 Version LT Version

0— —
1 A3 (lengthwise) 11" X 17"
2 B4 (lengthwise) 8
3 A4 (sideways) 11" X 8
4 A4 (lengthwise) 8
5 B5 (sideways) —
6 B5 (lengthwise) F (8" x 13"/lengthwise)
7—F4 (8
8 F (8" x 13"/lengthwise) Folio (8

9F4 (8
10 Folio (8
11 11" x 8
12 8

1/2" x 13"/lengthwise) 11" X 15"

1/4" x 13/ lengthwise) 10" X 14"

1/2" 8" X 101/2"

1/2" x 11" 8" X 10"

13 8K (267 mm x 390 mm/lengthwise) A4 (sideways)
14 16K (267 mm x 195 mm/sideways) A4 (lengthwise)
15 16K (195 mm x 267 mm/lengthwise) —

1/2" X 14"

1/2"

1/2" X 11"

1/2" x 13"/lengthwise)

1/4" x 13"/lengthwise)

Paper size SP settings for by-pass feed

(See Detailed Descriptions, section 11.9.3)

SP Settings A4 Version LT Version

0 Paper size detected in accordance

with the side fence position

1 A4 (lengthwise) 8

Paper size detected in accordance
with the side fence position

1/2" x 11"

2 A4 (sideways) B5 (lengthwise)

3 A5 (lengthwise) A6 (lengthwise)

4 A5 (sideways) F (8" x 13"/lengthwise)

5 A3 (lengthwise) F4 (8

6 Folio (8

1/4" x 13"/lengthwise) Folio (81/4" x 13"/length wise)

1/2" x 13"/lengthwise)

7 — 10" x 14"

8 — 8K (267 mm x 390 mm/lengthwise)

9 — 16K (267 mm x 195 mm/side ways)
10 — 16K (195 mm x 267 mm/lengthwise)

Paper size SP settings for the LCT

SP Settings A4 Version LT Version

0— —

1 11" x 8

2 A4 (sideways) A4 (sideways)

1/2" 11" x 81/2"

5. Leave SP mode by pressing the "Clear Modes" key three times.

FSM 4-49 FT5535/4527/4522