Ricoh FT 5560 Service Manual
RICOH FT5560
RICOH COMPANY, LTD.
FIELD SERVICE
MANUAL
TABLE OF CONTENTS
I. INSTALLATION
INSTALLATION REQUIREMENTS
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Minimum Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
COMPONENT INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . 1-6
SYSTEM CONFIGURATION TABLE . . . . . . . . . . . . . . . . . . . . .
How to Use
PAPER BANK INSTALLATION
Accessory Check . . .
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . .
. . . . .
1-7
1-8
1-9
LARGE CAPACITY TRAY INSTALLATION
Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Installation Procedure With Paper Bank
(5th feed station) .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-17
Installation Procedure Without Paper Bank
(3rd feed station)
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 1-17
Common Procedure for LCT Installation . . . . . . . . . . . . . 1-19
COPIER INSTALLATION
Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Installation Procedure . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
1-26
Cassette Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Key Counter Holder Installation . . . . . . . .
. . . . . . . . . . .
1-35
Accessory Counter Installation . . . . . . . . . . . . . . . . . . . . 1-37
DUPLEX UNIT INSTALLATION
Accessory Check . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
1-38
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
MINI SORTER INSTALLATION
Accessory Check . .
Removal of Shipping Retainers . . . . .
Adapter Accessory Check
Installation Procedure . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
1-46
1-46
1-47
1-48
MIDI SORTER INSTALLATION
Accessory Check . .
Removal of Shipping Retainers . . .
Adapter Accessory Check . . . .
Installation Procedure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-51
1-51
1-52
1-53
DOCUMENT FEEDER INSTALLATION
Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
1-57
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
AUTO REVERSE DOCUMENT FEEDER
Accessory Check . . . . .
Installation Procedure . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
1-66
1-68
COLOR UNIT INSTALLATION
Accessory Check . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . . . . . .
1-75
1-76
PREPARATION FOR TRANSPORTING THE COPIER
Short Haul Transportation . . . . . . . . .
Long Haul Transportation By Vehicle .
. . . . . . .
. . . . . . . . .
. . . . . . . . . . . . . .
1-79
1-81
II. SERVICE TABLES
SERVICE PROGRAM MODE OPERATION
Data Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Change Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Service Program Mode Table . .
Input Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
User Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . .
. . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . .
2-6
2-8
2-32
Ill. REPLACEMENT AND ADJUSTMENT
OPTICS
1. Fiber Optics Cable Replacement . . . . . . . . . . . . . . . . . 3-1
2. Auto Paper Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3. Length Sensing Adjustment . . . . . . . . . . . . . . . . . . . . . . 3-5
DEVELOPMENT AND TONER SUPPLY
1. Image Density Sensor Removal
2. Image Density Check and Adjustment
3. Toner Supply Clutch Disassembly
CLEANING
1. Cleaning Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
2. Pick-off Pawl Replacement . . . . . . . . . . . . . . . . . . . . . . 3-12
3. Bias Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4. Bias Roller Blade Replacement . . . . . . . . . . . . . . . . . . 3-15
PRE-QUENCHING
1. Pre-Quenching Corona Unit Replacement . . . . . . . . . . 3-16
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . .
. . . . . . .
3-6
3-7
3-9
PAPER FEED
1. Feed Roller/Friction Pad Gap Adjustment . . . . . . . . 3-17
2. Registration Clutch Adjustment . . . . . . . . . .
. . . . . . . .
3-18
FUSING
1. Checking Hot Roller Temperature . .
2. Changing Hot Roller Temperature
3. Fusing Pressure Adjustment . . . . .
4. Entrance Guide Height Adjustment
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . .
. . . . . . . . . . .
. . . . . . . . . . . . . . .
3-19
3-20
3-21
3-22
COPY IMAGE
1. Light Intensity Adjustment . . . . . . . . . . . . . . . . . . . . . 3-23
2. Auto ID Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . 3-26
3. Horizontal Magnification Adjustment . . . . . . . . . . . . 3-28
4. Vertical Magnification Adjustment
5. Lead Edge Registration Adjustment . .
6. Lead Edge Erase Margin Adjustment . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . .
. . . . . . .
3-29
3-30
3-32
CORONA
1. Charge Corona Wire Replacement . . . . . . . . . . . . . . . . . 3-34
2. Charge Cleaner Drive Wire Replacement . . . . . .
. . . .
3-36
3. Pre-Quenching Corona Wire Replacement . . . . . . . . . . 3-37
DRUM CURRENT ADJUSTMENTS
1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-41
2. Charge Corona
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . .
3. Transfer Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
4. Separation Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
5. Pre-cleaning Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
6. Pre-quenching Corona . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
LARGE CAPACITY TRAY
l. Tray Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
2. Tray Down Sensor and Positioning
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3. Paper Size Sensor Replacement . . . . . . . . . . . . . . . . . . 3-55
4. Side Registration Adjustment . . . . . . . . . . . . . . . . . . . 3-56
DUPLEX UNIT
1. Positioning Roller and Drive Belt Replacement . . 3-58
2. Positioning Roller Pressure Adjustment . . . . . . . . . 3-59
3. Jogger Home Position Adjustment . . . . . . . . . . . . . . . . 3-60
MIDI
DOCUMENT FEEDER ARDF
SORTER
Bin Drive Belt Replacement .
1.
2.
Bin Drive Motor Replacement
Bin Replacement .
3.
4.
Exit Roller Drive Motor Replacement .
Lower Exit Roller Unit and
5.
Exit Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-66
1. DF Belt Drive Motor Speed Adjustment
2. DF Registration Adjustment . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . .
. . . . . . . . .
. . . . . . . . . . .
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
3-61
3-63
3-64
3-65
3-68
3-70
IV. ELECTRICAL DATA
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
SECTION I
INSTALLATION
I. INSTALLATION
lnstallation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Component Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
System Configuration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Paper Bank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Large Capacity Tray lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Copier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Duplex Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Mini Sorter lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-46
Midi Sorter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Document Feeder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Auto Reverse Document Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Color Unit lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Preparation for Transporting the Copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
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 Illumination: Less than 1,500 Iux (Do not expose to direct sunlight)
4. Ventilation: Room air should turn over at least 3 times/hour.
3
5. Ambient Dust: Less than 0.15 mg/m
6. Room Size: More than 10 m
3
7. If the installation place 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 in sum-
mer.
(4 x 10¯³ oz/yd3)
(13.4 yd3)
31 March 1987
c. Where it will not be directly exposed to reflected heat from a space heater in
winter.
31 March 1987
8. Avoid placing the copier in an area filled with corrosive gas.
9. Avoid any area higher than 2,000 meters (6,500 feet) above sea level.
10. Place the copier on a strong and level base.
11. Avoid any area where the copier may be subjected to frequent strong vibration.
1-2
MACHINE LEVEL
1. Front to back: Within 5 mm (0.2”) of level
2. Right to left: Within 5 mm (0.2”) of level
31 March 1987
(Legs may be screwed up or down to level the machine. Set a carpenter’s level
the exposure glass.)
[A] on
31 March 1987
MINIMUM SPACE REQUIREMENTS
1-4
POWER REQUIREMENTS
1.
Input voltage level
110V/60Hz : More than 15A
115V/60Hz : More than 15A
220V/50Hz : More than 7A
240V/50Hz : More than 7A
2.
Permissible voltage fluctuation: 10%
31 March 1987
3.
Permissible extension cord:
At least 300V, 30A capacity and less than 5 meters
(16.4 ft) long.
NOTES: a)
Be sure to ground the machine. (Do not connect the grounding wire to a gas
pipe.)
b)
Make sure the plug is firmly inserted in the outlet.
Avoid multi-wiring.
c)
Do not set anything on the power cord.
4.
1-5
31 March 1987
COMPONENT INSTALLATION PROCEDURE
1.
Paper Bank
2.
Large Capacity Tray
Copier
3.
Auto Duplex Unit
4.
Sorter
5.
Document Feeder
6.
The illustration to the right shows the relative order of installing the different components to the
base copier to obtain the system configuration
desired by the customer. This installation proce-
dure has been tailored to this illustration. The installation of components should start from the
lower numbered components and progress to
higher numbered components.
NOTE: When not instaIling the duplex unit or the
sorter save the duplex unit or sorter key
tops and key covers for future use.
1-6
31 March 1987
SYSTEM CONFIGURATION TABLE
Use this table to determine what extra equipment is required to install the optional equipment.
Duplex
Sorter
Duplex Unit
Large Capacity
Tray
Paper Bank
(4th and 5th
Cassette)
Unit
Without
Duplex
Unit
Interface
Board Adapter
(Note 2)
*
* *
*
Sorter
System Optional
Table Cassette
* *
(Note 1)
NOTE 1: All copiers have three cassettes as accessories.
NOTE 2: If the copier already has an ADF, sorter, or duplex unit installed, you do not need an in-
terface board.
1-7
31 March 1987
HOW TO USE:
As shown in the following example, check off each piece of optional equipment to be installed. For each checked item,
Check off each piece of required
the asterisks to the right show the required equipment.
equipment.
Auto Document
Feeder
With
Duplex
Sorter
Duplex Unit
Large Capacity
Tray
Paper Bank
(4th and 5th
Cassette)
Unit
Without
Duplex
Interface Sorter
Board Adapter
(Note 2)
*
System
Table Cassette
* *
Optional
(Note 1)
31 March 1987
PAPER BANK INSTALLATION
ACCESSORY CHECK
Check the quantity and condition of the accessories in the box according to the following
list:
1. Installation procedure
(115V - English only, 220V - five languages)
2. New Equipment Condition Report
3. Envelope - NECR (115V only)
4. Expansion docking bracket
5. Expansion docking plate
6. Mylar paper guide
7. Expansion relay roller unit
8. Spring
9. Nylon wire clamp - large (10N)
10. Nylon wire clamp - small (4N)
11. Bank docking bracket
12. Pan head screw - M4 X 8
13. Pan head screw with washer - M4 X 8
14. Shoulder screw
15. Decal - Misfeed
16. Multilingual decals (220/240V only) 1 set
(115V - English only, 220V - five languages)
1
1
1
2
2
1
1
1
1
1
1
16
2
1
1
1-9
31 March 1987
INSTALLATION PROCEDURE
1. Remove the strips of shipping tape [A].
2. Remove the right side of the system table
[B] (5 screws).
3. Install the front and rear expansion docking
brackets [C] on the system table as shown
(2 screws each).
Note: If an LCT is to be installed in the system,
first perform the following:
4.
5.
1-10
6. Remove the front [A] and rear [B] covers
from the expansion unit (2 screws each).
7. Adjust the height of the paper bank:
a. Remove the internal cover [C] from the
paper bank (2 screws).
b. Using the height adjusting bolts [D], raise
or lower the paper bank so that both the
front [E] and rear [F] screw holes of the
paper bank and expansion unit align.
c. Secure the paper bank to the expansion
unit (2 screws).
d. Open the system table front door [G],
swing out the 4th paper feed station [H],
and secure the paper bank to the front
side of the system table (1 screw).
e. Remove the bank rear cover [I] and the
bank rear right cover [J] (2
screws
each), then secure the bank to the rear
side of the system table (1 screw).
f. Install the bank docking bracket [K] (2
screws).
g. Install the internal cover to the paper
bank (2 screws).
8. Install the front [L] and rear [M] expansion
docking plates as shown (2 screws each).
31 March 1987
1-11
31 March 1987
9.
Remove the front right [A] and rear right [B]
covers of the expansion unit (front - 2
screws, rear - 1 screw).
10.
Remove the right side safety switch assembly [C] (1 screw).
11.
Remove the copier rear cover (4 screws)
lower the PCB plate (2 screws), and disconnect the expansion interface harness from
the copier.
12.
Pull the 3rd feed unit out [D] (4 screws).
13.
System without duplex unit only:
Install the mylar paper guide [E] on the expansion relay roller unit.
1-12
14.
While doing this step:
a. Run the expansion relay unit harness [A]
(except the clutch harness) through the
harness access hole [B] on the rear side of
the 3rd paper feed unit [C].
b. Set the front of the relay unit before set-
ting the hook on the rear.
Mount the expansion relay roller unit [D] on
the 3rd feed unit. (front: 1 screw and 2
hooks, rear: 1 shoulder screw and 1 hook).
Hook the spring [E] between the guide plate
15.
lever [F] and the 3rd feed unit mounting
bracket.
While doing this step, you must pass the ex-
16.
pansion interface harness and the safety
switch assembly around their respective expansion unit uprights.
Plug the 5P connector (red) [G], into CN912
of the 3rd paper feed PCB [H], connect the
other end to the expansion relay clutch [I],
and clamp the harnesses with the twist
clamp [J].
Reinstall the 3rd paper feed unit and the
17.
safety switch assembly (1 screw) in the expansion unit (4 screws).
31 March 1987
1-13
31 March 1987
1-14
18.
Connect the bank interface harness [A] to
the 3rd paper feed PCB [B] as shown.
Clamp the bank interface harness to the
19.
bank docking bracket [C] with the large
nylon wire clamp [D] (1 screw with washer).
20.
a. Connect the ac paper bank harness [E]
to the copier and clamp the harness with
the small nylon wire clamp [F] on the left
image plate of the PCB plate [G] as
shown (1 screw with washer).
b. When doing this step, run the harness
from the left side of the PCB plate so
that the rear cover may close properly.
Connect the 9P expansion interface harness connector [H] to CN606 of the
paper feed PCB [I] and 2 free connectors (8P [J] and 6P [K]) to free connectors from the dc harness.
c. Fix the expansion interface harness to
the left hinge plate of the PCB plate with
the nylon wire clamp [L] (1 screw with
washer).
Stick the “Misfeed E” decal [A] on the front
21.
cover of the expansion unit as shown.
When reinstalling the expansion rear cover,
22.
place the bank ac harness inside the expansion unit.
Reinstall all covers except under the follow-
23.
ing conditions.:
If the LCT is to be installed, leave off
the bank rear cover.
If the duplex unit is to be installed, leave
off the expansion rear cover.
Leave off the copier rear cover if the du-
plex unit, DF, and/or sorter are to be installed.
24. Fill out the New Equipment Condition Report.
31 March 1987
1-15
31 March 1987
COPIER INSTALLATION
ACCESSORY CHECK
Check the quantity and condition of the accessories in the box according to the following
list:
1. Installation procedure
(115V - English only, 220V - five languages)
2. New Equipment Condition Report
3. Envelope - NECR (115V only)
4. Cassette - large
5. Cassette - small
6. Receiving tray
7. Original holder
8. Editing sheet
9. Operating instructions
(115V - English only 220V - five languages)
10. Operating instruction cards
(115V - English only 220V - five languages)
11. Sort/Stack Key Cover
12. Sort/Stack Key Top
13. Duplex Key Cover
14. Duplex Key Top
15. Multilingual decals (220/240V only)
If not installing the duplex unit or sorter, save the duplex unit and sorter key tops and key
covers for future use.
1
1
1
1
2
1
1
1
1
1 set
1
1
1
1
1 set
1-25
31 March 1987
INSTALLATION PROCEDURE
1.
Remove the shipping tape [A] from the copier as shown.
Open the copier front cover [B], remove the
2.
shipping tape [C] and the wedge [D] between the registration rollers as shown.
Remove the copier scanner lock plate
3.
cover [E] (1 screw).
Remove the copier scanner lock plate [F] (1
4.
screw).
Save the scanner lock plate for future
use.
Reinstall the copier scanner lock plate
5.
cover.
1-26
6. Remove the fusing lock plate [A] (2
screws).
7. Use one of the screws removed in the previous step to secure the inner cover [B].
8. Pull out the fusing unit [C] to the lock position and remove the fusing unit cover [D] (2
screws).
9. Prime the oil supply pad [E] with silicon oil.
10. Fill the oil tank [F] with silicon oil.
11. Manually operate the oil pump lever [G] and
confirm proper operation and condition of
the silicon oil supply system.
12. Reassemble the fusing unit and return it to
its original position.
1-27
31 March 1987
13. Raise the development lock lever [A] and
pull out the development unit [B]. Place the
unit on a clean sheet of paper.
14. Separate the toner tank [C] from the development unit [D] (2 screws).
15. Pour one bottle [E] of developer into the development unit while turning the knob [F]
counterclockwise to distribute the developer.
16. Remount the toner tank on the development
unit.
1-28
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