A095/A096/A097

SERVICE MANUAL
RICOH GROUP COMPANIES PN: RCFM6655
®

RICOH GROUP COMPANIES

®

A095/A096/A097
SERVICE MANUAL
A095/A096/A097
SERVICE MANUAL

PN: RCFM6655
WARNING
The Service Manual contains information regarding
service techniques, procedures, processes and
spare parts of office equipment distributed by
Ricoh Corporation. Users of this manual should be
either service trained or certified by successfully
completing a Ricoh Technical Training Program.

Unt rained and uncer tified users utilizing

information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.

Ricoh Corporation
LEGEND
PRODUCT CODE COMPANY
GESTETNER RICOH SAVIN
A095 2545D FT6645 9450
2555D FT6655 9550
2565D FT6665 9650

DOCUMENTATION HISTORY

REV. NO. DATE COMMENTS

* 10/93 Original Printing
1 1/94 Revised pages
2 4/94 Revised pages
3 6/94 Revised pages
4 7/94 A097 addition
Rev. 7/94

Table of Contents

OVERALL MACHINE INFORMATION

1. SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

COMPONENT LAYOUT AND DESCRIPTION

1. MACHINE CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.1 COPIER OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

1.2 SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . 2-4

3. DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

4. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . 2-7

INSTALLATION

1. INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.1 ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.2 MACHINE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

1.3 MINIMUM SPACE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

1.4 POWER REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

2. COPIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

2.2 COPIER INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

2.3 GUIDANCE ROM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

2.4 PLATEN COVER (OPTION) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-14

2.5 PAPER SIZE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

2.5.1 550 Sheet Paper Tray (1st and 3rd feed stations for A095 copier) . . . . . 3-15

2.5.2 1500 Sheet Paper Tray (3rd feed station for A096/A097 copier). . . . . . . 3-17

FSM i A095/A096/A097
Rev. 7/94

2.6 KEY COUNTER HOLDER INSTALLATION (OPTION) . . . . . . . . . . . . . . . . . . 3-18

2.7 IMAGE DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

SERVICE TABLES

1. SERVICE REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.1 HANDLING THE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1.2 DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.3 CHARGE CORONA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

1.4 OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.5 ERASE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

1.6 DEVELOPMENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

1.7 TRANSFER BELT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

1.8 CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

1.9 PRE-TRANSFER LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.10 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

1.11 FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

2. SERVICE PROGRAM MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.1 SERVICE PROGRAM MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.1.1 Service Program Access Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.1.2 To Exit SP Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

2.1.3 To Return to the Index Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1.4 Change the Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.1.5 Access to "Copy in SP" Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

2.2 SERVICE PROGRAM MODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

2.3 SENSOR/SWITCH/SIGNAL DATA CHECK (INPUT MODE) . . . . . . . . . . . . . 4-36

2.4 ELECTRICAL COMPONENT CHECK (OUTPUT MODE) . . . . . . . . . . . . . . . 4-42

2.5 USER TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

2.5.1 User Tools Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

2.5.2 How To Access The User Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

3. TEST POINTS / CHECK POINTS . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

A095/A096/A097 ii FSM
Rev. 4/15/94

3.1 MAIN CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

3.2 OPTICS CONTROL BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

3.3 OPERATION PANEL BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

4. PREVENTIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . 4-57

4.1 PM TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

4.2 EXPLANATION OF REGULAR PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4.3 REGULAR PM PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

REPLACEMENT AND ADJUSTMENT

1. EXTERIOR AND INNER COVER REMOVAL. . . . . . . . . . . . . . . . . 5-1

1.1 FRONT SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1.1 Left Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.1.2 Right Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

1.2 REAR SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.2.1 Upper Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.2.2 Lower Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

1.2.3 Left Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

1.2.4 Right Inner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

1.2.5 Shutter Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

1.3 RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

1.3.1 Feed Unit Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

1.3.2 Upper Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

1.3.3 Lower Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

1.4 LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1.4.1 Upper Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1.4.2 Lower Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1.5 OPERATION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

1.6 UPPER SIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

1.6.1 Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

1.6.2 Rear Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

FSM iii A095/A096/A097

Rev. 4/15/94

2. OPTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
2.1 EXPOSURE GLASS REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

2.2 EXPOSURE LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

2.3 OPTICS THERMOSWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 5-13

2.4 SCANNER HP SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

2.5 ADS SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

2.6 SCANNER DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

2.7 SCANNER DRIVE WIRES REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 5-17

2.8 SCANNER CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

2.9 THIRD SCANNER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

2.10 THIRD SCANNER DRIVE MOTOR / HP

SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

2.11 LENS HORIZONTAL DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . 5-35

2.12 LENS VERTICAL DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5-37

2.13 ORIGINAL SIZE SENSORS (2 LENGTH SENSORS, 1 WIDTH SENSOR)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

3. DEVELOPMENT AND TONER SUPPLY. . . . . . . . . . . . . . . . . . . 5-39

3.1 DEVELOPMENT UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

3.2 DEVELOPER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

3.3 DEVELOPMENT ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5-43

3.4 TONER DENSITY SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5-46

3.5 TONER BOTTLE DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . 5-47

4. DRUM UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

4.1 DRUM UNIT REMOVAL AND OPC DRUM
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

4.2 QUENCHING LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

4.3 GRID PLATE / CHARGE WIRE / WIRE

CLEANER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

4.4 ERASE LAMP AND DRUM POTENTIAL

SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

A095/A096/A097 iv FSM
Rev. 7/94

4.5 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

4.6 CLEANING BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

4.7 PICK-OFF PAWL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

4.8 TONER COLLECTION COIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 5-56

4.9 OZONE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5. TRANSFER BELT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

5.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . 5-61

5.2 TRANSFER BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

5.3 CLEANING BLADE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

6. PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

6.1 PAPER TRAY UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

6.2 PAPER TRAY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

6.3 PAPER FEED ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

6.4 TANDEM REAR FENCE DRIVE BELT REMOVAL

(A096/A097 copier only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

6.5 TANDEM SIDE FENCE MOTOR REMOVAL

(A096/A097 copier only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

6.6 PAPER FEED TIMING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

6.6.1 Paper Feed Timing Adjustment FT6645/6655 (A095/A096) Only . . . . . . 5-74

6.6.2 Paper Feed Timing Adjustment FT6645/6655 (A097) Only . . . . . . . . . 5-74A

6.7 PAPER FEED CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

6.8 BY-PASS FEED TABLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

6.9 BY-PASS FEED ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5-80

6.10 BY-PASS PAPER SIZE SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . 5-82

6.11 BY-PASS FEED CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

6.12 REGISTRATION CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86

6.13 PAPER DUST CLEANER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

6.14 REGISTRATION SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

6.15 COPIER FEED UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

6.16 TANDEM FEED TRAY PAPER SIZE CHANGE . . . . . . . . . . . . . . . . . . . . . . 5-91

FSM v A095/A096/A097
Rev.6/13/97

6.17 UNIVERSAL TRAY PAPER SIZE CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . 5-95

7. FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

7.1 FUSING UNIT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

7.2 FUSING THERMISTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

7.3 FUSING THERMOFUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98

7.3.1 Fusing Thermofuse Replacement FT6645/6665 (A095/A096) Only . . . . 5-98

7.3.2 Fusing Thermofuse Replacement FT6665 (A097) Only . . . . . . . . . . . 5-98A

7.4 FUSING LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98B

7.4.1 Fusing Lamp Replacement FT6665 (A097) Only . . . . . . . . . . . . . . . . . 5-98B

7.4.2 Fusing Lamp Replacement FT6645/6655 (A095/A096) Only . . . . . . . . . 5-99

7.5 HOT ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

7.6 PRESSURE AND BEARING ROLLER REPLACEMENT . . . . . . . . . . . . . . 5-102

7.7 FUSING STRIPPER PAWL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . 5-103

7.8 FUSING PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104

7.9 PAPER EXIT UNIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105

7.10 OIL SUPPLY ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

8. DUPLEX UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109

8.1 FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109

8.2 SEPARATION BELTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

8.3 DUPLEX UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113

8.4 SEPARATION CLUTCH/TRANSPORT CLUTCH REMOVAL . . . . . . . . . . . 5-114

8.5 JOGGER MOTOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115

9. COPY QUALITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 5-120

9.1 SP Adjustment Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120

9.2 SIDE-TO-SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 5-122

9.3 UNEVEN EXPOSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123

9.4 IMAGE DENSITY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125

9.5 SCANNER HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126

10. TOUCH PANEL DISPLAY ADJUSTMENT . . . . . . . . . . . . . . . . 5-129

⇒ 11. SERVICE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130

A095/A096/A097 vi FSM
Rev. 2/17/95

TROUBLESHOOTING

1. SERVICE CALL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.1 SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1.2 EXPOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

1.3 SCANNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

1.4 LENS MAGNIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

1.5 OPTICS THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

1.6 MAIN CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

1.7 DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

1.8 PROCESS SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

1.9 TRANSFER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

1.10 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

1.11 PAPER FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

1.12 DUPLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

1.13 FUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

1.14 SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

1.15 DUAL JOB FEEDER/RECIRCULATING

DOCUMENT HANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

1.16 FINISHER / SORTER STAPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

1.17 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

2. ELECTRICAL COMPONENT DEFECTS . . . . . . . . . . . . . . . . . . . 6-24

2.1 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

2.2 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

2.3 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

2.3.1 DC Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

3. COPY QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

4. MISFEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

5. MACHINE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6. ROM MODIFICATION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

FSM vii A095/A096/A097

Rev. 7/94

DUAL JOB FEEDER (DF60)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

3. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . 7-4

4. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

4.2 INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

5. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

5.1 DIP SWITCHES AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

5.2 VARIABLE RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

5.3 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

5.4 FUSEs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

6. REPLACEMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . 7-13

6.1 TRANSPORT BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

6.2 FEED ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

6.3 SEPARATION BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

6.4 FEED-OUT MOTOR (FEED-OUT UNIT) REMOVAL . . . . . . . . . . . . . . . . . . . 7-19

6.5 INVERTER SOLENOID REMOVAL AND ADJUSTMENT . . . . . . . . . . . . . . . 7-21

6.6 BELT DRIVE MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

6.7 FEED-IN CLUTCH (FEED-IN UNIT) REMOVAL. . . . . . . . . . . . . . . . . . . . . . . 7-25

6.8 STOPPER SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

6.9 VERTICAL REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

6.9.1 One Sided Original Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

6.9.2 Two Sided Original Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

6.9.3 Combine 2 Originals Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

6.10 SIDE TO SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 7-31

A095/A096/A097 viii FSM

Rev. 4/15/94

6.11 MOTOR SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

SORTER STAPLER (ST25)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. COMPONENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

2.2 DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

3. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . 8-5

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

4.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

5. SERVICE TABLES (MAIN CONTROL BOARD) . . . . . . . . . . . . . 8-13

5.1 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

5.2 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

5.3 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

6. REPLACEMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . 8-15

6.1 EXTERIOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

6.2 STAPLER REMOVAL AND REINSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8-17

6.3 JOGGER PLATE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . 8-18

6.4 BINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

6.5 MAIN MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

6.6 GRIP ASSEMBLY REMOVAL, AND GRIP SOLENOID AND GRIP

POSITIONING SOLENOID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

6.7 MAIN CONTROL BOARD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

6.8 STAPLE POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

6.9 HELICAL WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

FSM ix A095/A096/A097
Rev. 4/15/94

RECIRCULATING DOCUMENT HANDLER (DH400)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . 9-2

3. ELECTRICAL COMPONENT DESCRIPTIONS . . . . . . . . . . . . . . . 9-3

4. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

4.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

5. SERVICE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

5.1 TEST POINT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

5.2 FUSE TABLE (Main Board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

5.3 LED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

5.4 DIP SWITCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

6. REPLACEMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . 9-12

6.1 TRANSPORT BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

6.2 PAPER FEED ROLLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

6.3 FRICTION BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

6.4 PAPER EXIT TRANSPORT BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 9-15

6.5 RDH MAIN CONTROL BOARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

6.6 RDH LEADING EDGE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . 9-17

6.7 MOTOR SPEED CHECK & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

FINISHER (SR400)

1. OVERALL MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . 10-1

1.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

1.2 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

1.3 ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 10-4

1.4 DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

A095/A096/A097 x FSM
Rev. 4/15/94

2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
2.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

2.2 INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

3. SERVICE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

3.1 TEST POINT TABLE (Main Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

3.2 FUSE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

3.3 LED TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

3.4 DIP SW TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

3.4.1 Factory Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

3.4.2 Motor Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

3.4.3 Free Run Test Mode Without Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

3.4.4 Off Line Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

4. REPLACEMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 10-16

4.1 EXTERIOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

4.2 ALIGNMENT BRUSH ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . 10-17

4.3 SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

4.4 POSITIONING ROLLER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

4.5 BELT TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

11. LARGE CAPACITY TRAY (RT31)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

2. MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . 11-2

3. ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . 11-3

4. INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

4.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

4.2 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

4.3 PAPER SIZE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

5. REPLACEMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 11-15

FSM xi A095/A096/A097
5.1 PAPER FEED ROLLERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

5.2 LCT FEED CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16

5.3 UPPER COVER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17

5.4 SIDE-TO-SIDE REGISTRATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 11-18

12. SORTER STAPLER (ST24)

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

2. COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

2.1 MECHANICAL COMPONENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

2.2 DRIVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

2.3 ELECTRICAL COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 12-5

3. INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

3.1 ACCESSORY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

3.2 INSTALLATION PROCEDURE

(for Machine Code:A095 copier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

4. SERVICE TABLE (MAIN CONTROL BOARD) . . . . . . . . . . . . . 12-14

4.1 DIP SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

4.2 LED and Variable Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

4.3 TEST POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

5. REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 12-15

5.1 STAPLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

5.2 GRIP ASSEMBLY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

5.3 BIN REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

5.4 BIN LIFT WIRE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

5.4.1 Wire Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

5.4.2 Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-24

5.5 VERTICAL TRANSPORT UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 12-25

A095/A096/A097 xii FSM

5.6 MAIN CONTROL BOARD REPLACEMENT
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

5.6.1 Main Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-26

5.6.2 Bin Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27

5.7 BELT TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-28

BULLETINS

FSM xiii A095/A096/A097

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 some components of the copier and the paper tray unit 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. If the hot roller temperature is low when the main switch is turned on, the
copier starts idling automatically when the warm-up period is completed.
Keep hands away from the mechanical and the electrical components to
avoid any injury.
6. If the start key is pressed before the copier completes the warm-up
period (Ready indicator starts blinking), keep hands away from the
mechanical and the electrical components as the copier starts making
copies as soon as the warm-up period is completed.
7. 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. Never operate the copier without the ozone filters installed.
2. Always replace the ozone filters with the specified ones at the specified
intervals.
3. 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.

a
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 -
The RAM board on the main control board has a lithium battery which
can explode if replaced incorrectly. Replace the battery only with an
identical one. The manufacturer recommends replacing the entire RAM
board. Do not recharge or burn this battery. Used batteries must be
handled in accordance with local regulations.

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Do not incinerate the toner cartridge or the used toner. Toner dust may
ignite suddenly when exposed to open flame.
2. Dispose of used toner, developer, and organic photoconductor
according to local regulations. (These are non-toxic supplies.)
3. Dispose of replaced parts in accordance with local regulations.
4. When keeping used lithium batteries in order to dispose of them later, do
not put more than 100 batteries per sealed box. Storing larger numbers
or not sealing them apart may lead to chemical reactions and heat
build-up.

b
TAB INDEX

TAB POSITION 8 TAB POSITION 7 TAB POSITION 6 TAB POSITION 5 TAB POSITION 4 TAB POSITION 3 TAB POSITION 2 TAB POSITION 1
OVERALL MACHINE INFORMATION
RECIRCULATING DOCUMENT HANDLER A378

COMPONENT LAYOUT AND DESCRIPTION

FINISHER A379

INSTALLATION
LARGE CAPACITY TRAY A380

SERVICE TABLES
SORTER STAPLER A374

REPLACEMENT AND ADJUSTMENT

TROUBLESHOOTING

DUAL JOB FEEDER A376

SORTER STAPLER A377

OVERALL MACHINE
INFORMATION
1. SPECIFICATION
Configuration: Console

Overall Machine
Information
Copy Process: Dry electrostatic transfer system
Toner Supply Control: Fuzzy Control
Photoconductor: OPC drum
Originals: Sheet/Book
Original Size: Maximum A3/11" x 17"
Original Alignment: Left rear corner
Copy Paper Size: Maximum A3/11" x 17"
Minimum A5/51/2" x 81/2" (Tray)
B5/81/2" x 11" (1.5K LCT)
A6/51/2" x 81/2" (By-pass)
Duplex Copying: Maximum A3/11" x 17"
Minimum A5/51/2" x 81/2" (sideways)
Copy Paper Weight: Paper tray: 52 ~ 128 g/m2, 14 ~ 34 lb
Bypass feed table: 52 ~ 157 g/m2, 14 ~ 42 lb
Duplex copying: 64 ~ 104 g/m2, 17 ~ 24 lb
Reproduction Ratios: 4 Enlargement and 6 Reduction

A4/A3 Version LT/LDG Version

Enlargement 200% 200%
141% 155%
122% 129%
115% 121%
Full Size 100% 100%
Reduction 93% 93%
82% 85%
75% 77%
71% 74%
65% 65%
50% 50%

FSM 1-1 A095/A096/A097

Rev. 7/94
Power Source: 115V, 60Hz, more than 20A (for N.A)
220 ∼ 240V, 50Hz/60Hz, more than 10A (for EU
and AA)
Power Consumption: FT6645 (A095) and FT6655 (A096) copiers

Copier only Full system*

Warm-up 0.90 kVA 0.90 kVA
Stand-by 0.25 kVA 0.25 kVA
Copying 1.20 kVA 1.30 kVA
Maximum 1.45 kVA 1.50 kVA

FT6665 (A097) copier

Copier only Full system*

120 V 230 V 120 V 230 V
machine machine machine machine
Warm-up 1.20 kVA 1.20 kVA 1.25 kVA 1.25 kVA
Stand-by 0.25 kVA 0.22 kVA 0.25 kVA 0.24 kVA
Copying 1.80 kVA 1.70 kVA 1.80 kVA 1.75 kVA
Maximum 1.80 kVA 1.70 kVA 1.80 kVA 1.75 kVA

*Full System:
• Mainframe with dual job feeder, compact
sorter stapler and 3,500-sheet large capacity
tray
• Mainframe with dual job feeder, floor type
sorter stapler and 3,500-sheet large capacity
tray
• Mainframe with recirculating document
handler, finisher and 3,500-sheet large
capacity tray

A095/A096/A097 1-2 FSM

Rev. 7/94
Noise Emission:
Copier only Full system*

Overall Machine
Copying (FT6645/6655 copiers) 55 dB (A) 62 dB (A)

Information
Sound Pressure Level: Copying (FT6665 copier) 60 dB (A) 64 dB (A)
The measurements are
made according to Full System:
ISO7779
• Mainframe with dual job feeder, compact
sorter stapler and 3,500-sheet large capacity
tray
• Mainframe with dual job feeder, floor type
sorter stapler and 3,500-sheet large capacity
tray
• Mainframe with recirculating document
handler, finisher and 3,500-sheet large
capacity tray

Dimensions: 690 x 690 x 980 (W x D x H Mainframe only)

1280 x 690 x 1020 (W x D x H Mainframe with
copy tray, platen cover)
Weight: Copier only: (Without the optional platen cover
= Approximately 2 kg)
FT6645 (A095) copier: Approximately (333 lbs)
FT6655 (A096) copier: Approximately (360 lbs)
FT6665 (A097) copier: Approximately (360 lbs)
Zoom: From 50% to 200% in 1% steps
Copying Speed:
A4/LT (sideways) A3/DLT B4/LG
FT6645 copier 45 23 27
FT6655 copier 55 28 35
FT6665 copier 65 33 41

Warm-up Time: Less than 5 minutes (20°C)

First Copy Time: 3.1 seconds FT6645/6655 (A095/A096 copiers)
(A4/81/2" x 11" sideways 2.7 seconds FT6665 (A097 copier)
from the 1st feed station)
Copy Number Input: Number keys, 1 to 999 (count up or count down)
Manual Image Density 7 steps
Selection:

FSM 1-3 A095/A096/A097

Rev. 7/94
Automatic Reset: 1 minute standard setting; can also be set from
1 second to 999 seconds or no auto reset.
Copy Paper Capacity: • By-pass feed table: approximately 50 sheets
• Paper tray: approximately 550 sheets
• Tandem tray: approximately 500 sheets/side,
1000 Total
• Large capacity tray: approximately 1500
sheets
• Duplex: 50 sheets

Toner Replenishment: 1,100 g/cartridge

Developer Black Only: 1Kg/Bag, 120,000 copies 6%

Replenishment: (originals)

Optional Equipment: • Type 610, Platen cover

• DF 60, Dual job feeder
• DH400, Recirculating document handler
• ST25, 20 bin sorter stapler (Floor type)
• ST24, 20 bin compact sorter stapler
• SR400, Finisher
• RT31, 3500-sheet Large capacity tray
• Type B, Receiving Tray

Toner Collection 7500cc, 120,000 copies (6% originals)

Bottle Capacity:

A095/A096/A097 1-4 FSM

COMPONENT LAYOUT
AND DESCRIPTION
Rev. 10/94
1. MACHINE CONFIGURATION
1.1 COPIER OVERVIEW
There are two types of mainframe.

FT6645 (A095) copier

Component
Description
Layout &
50

550
(3,500)
550
550
Three 550-sheet paper trays Optional
3,500-sheet large capacity tray

FT6655/6665 (A096/A097) copier

50

(3,500) Tandem paper tray

500 x 2 or 500 (including two 500-sheet paper tray)
One 550-sheet paper tray
550
1,500-sheet built-in large capacity tray
Optional 3,500-sheet large capacity
1,500 tray

FSM 2-1 A095/A096/A097

Rev. 10/94
1.2 SYSTEM OVERVIEW
System A
The mainframe FT6645 (A095) with dual job feeder and compact sorter
stapler.
Dual job feeder DF60 (A376)

Compact
sorter stapler
ST24 (A374)
3,500-sheets
large capacity
tray
RT31(A380)

System B
Mainframe type FT6645/6655/6665 (A095/A096/A097) with dual job feeder
and floor type sorter stapler. The mainframe in the illustration below is the
FT6655 (A096).
Dual job feeder DF60(A376)

3,500-sheets
Floor type large capacity
sorter stapler tray
ST25 (A377) RT31(A380)

A095/A096/A097 2-2 FSM

Rev. 10/94
System C
The mainframe FT6655/6665 (A096/A097) with recirculating document
handler and finisher.

Recirculating document handler DH400(A378)

Component
Description
Layout &
Finisher
SR400(A379) 3,500-sheets
large capacity
tray
RT31(A380)

NOTE: All references to (A096 copier only) now refers to (A096 and
A097 Copiers)

FSM 2-3 A095/A096/A097

2. MECHANICAL COMPONENT LAYOUT

3 5 6 7 8 9 10 11
4
12

2
13

14
1
15
39
16
38 17

37 18

19
20
36
21
22

23

24
25
26
27

35
28

34 30 29
33 32 31

A095/A096/A097 2-4 FSM

1. 3rd Mirror 21. Separation Roller, By Pass
2. 2nd Mirror 22. Registration Rollers
3. 1st Mirror 23. Transfer Belt

Component
Description
Layout &
4. Exposure Lamp 24. Vertical Transport Rollers
5. Lens 25. Tandem Tray (A096 copier)
550-sheet Tray (A095 copier)
6. Cleaning Brush
26. Universal Tray
7. Cleaning Blade
27. 1500-sheet LCT (A096 copier)
8. Quenching Lamp 550-sheet Tray (A095 copier)
9. Charge Corona Unit 28. Toner Collection Bottle
10. OPC Drum 29. Transfer Belt Cleaning Blade
11. 6th Mirror 30. Hot Roller
12. 4th Mirror 31. Pressure Roller
13. 5th Mirror 32. Jogger Fences
14. Erase Unit 33. Duplex Positioning Roller
15. Drum Potential Sensor 34. Duplex Pick-up Roller
16. Toner Hopper 35. Duplex Feed Roller
17. Development Unit 36. Separation Belt
18. Pre-Transfer Lamp 37. Junction Gate
19. Pick-up Roller, By Pass 38. Exit Rollers
20. Feed Roller, By Pass 39. Optics Cooling Fan

FSM 2-5 A095/A096/A097

3. DRIVE LAYOUT

❶
9 ❷
10 1
❾ 11

2
❽
3
4
5
❼ ❸
6
❻
❺

7 ❹

❶ Main Motor 1. OPC Drum

❷ Scanner Drive Motor 2. Scanner Unit
❸ Fusing/Duplex Drive Motor 3. Transfer Belt Unit
❹ Paper Feed Motor 4. Paper Exit Unit
❺ Toner Collection Motor 5. Fusing Unit

❻ Registration Clutch 6. Duplex Unit

❼ By-Pass Feed Motor 7. Paper Trays

❽ BY-Pass Feed Clutch 8. Paper Feed Units

❾ Development Drive Motor 9. Toner Hopper

10. Development Unit
11. Cleaning Unit

A095/A096/A097 2-6 FSM

4. ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the attached
Point to Point for symbols and index numbers.
Note: For RT31 descriptions, see Section 7, page 3.

Symbol Name Function Index

No.
Motors

Component
Description
Layout &
M 1 Scanner Drive Drives the 1st and 2nd scanners 42
(dc servo).
M 2 Exhaust Fan Removes the heat from around 43
the fusing unit.
M 3 Main Drives the main unit components. 44
M 4 Development Drive Drives the development unit. 45
M 5 By-pass Feed Drives the by-pass feed rollers. 46
M 6 3rd Scanner Drive Drives the 3rd scanner (dc 47
stepper)
M 7 Toner Bottle Drive Rotates the toner bottle to supply 48
toner to the toner hopper.
M 8 Charge Wire Drives the main charge wire 49
Cleaner Drive cleaner to clean the charge wire.
M 9 Jogger Drives the jogger fences to 50
square the paper stack in the
duplex tray (dc stepper).
M10 Lens Horizontal Drive Shifts the lens horizontal position. 51
M11 Lens Vertical Drive Shifts the lens vertical position. 52
M12 Optic Cooling Fan Removes heat from the optics 53
unit.
M13 Fusing/Duplex Drive Drives the fusing unit, the duplex 54
unit, and the paper exit rollers.
M14 Paper Feed Drives all feed and transport 90
rollers in the paper tray unit.
M15 1st Lift Raises the bottom plate in the 1st 91
paper tray.
M16 2nd Lift Raises the bottom plate in the 92
2nd paper tray.
M17 Toner Collection Transports the collected toner to 93
the toner collection bottle.

FSM 2-7 A095/A096/A097

Rev. 7/94

Symbol Name Function Index

No.
M18 3rd Lift Raises the bottom plate in the 94
(A095) 3rd paper tray.
M19 Side Fence Drive Opens and closes the front and 95
(A096/A097) the rear side fences of the
tandem tray.
M20 Rear Fence Drive Moves the papers stacked in the 96
(A096/A097) left tandem tray to the right
tandem tray.
M21 LCT Motor Lifts and lowers the LCT bottom 127
(A096/A097) plate to bring paper to the feed
position and allow loading of the
paper.

Magnetic Clutches
MC1 Toner Supply Turns the toner supply roller to 57
supply toner to the development
unit.
MC2 Registration Drives the registration rollers. 58
MC3 By-pass Feed Starts paper feed from the 60
by-pass feed table.
MC4 Duplex Transport Drives the duplex transport 64
rollers to transport the paper to
the vertical transport rollers.
MC5 Duplex Feed Starts paper feed from the duplex 65
tray to the duplex transport
rollers.
MC6 1st Feed Starts paper feed from the 1st 99
feed tray.
MC7 2nd Feed Starts paper feed from the 2nd 101
feed tray.
MC8 3rd Feed Starts paper feed from the 3rd 104
feed tray.

Switches
SW1 By-pass Table Detects if the by-pass feed table 25
is open or closed.

A095/A096/A097 2-8 FSM

Rev. 7/94
Symbol Name Function Index
No.
SW2 Front Door Safety Cuts the DC power line and 29
detects if the front door is open
or not.
SW3 1st Tray Set Detects if the 1st tray is set or not. 66
(A095)
SW4 2nd Paper Size Determines what size paper is in 67

Component
Description
the 2nd (universal) paper tray.

Layout &
SW5 Toner Overflow Detects when the toner collection 75
bottle is full.
SW6 Toner Collection Detects if the toner collection 77
Bottle Set bottle is set or not.
SW7 Lower Front Door Detects if the front door is open 83
Safety or not.
SW8 3rd Tray Set Detects if the 3rd tray is set or 84
(A095) not.
SW9 Main Provides power to the copier 122
SW10 Tray Down Lowers the LCT bottom plate. 126
(A096/A097)

Solenoids
SOL 1 Junction Gate Moves the junction gate to direct 55
copies to the duplex tray or to the
paper exit.
SOL 2 Duplex Positioning Controls the up-down movement 56
of the positioning roller.
SOL 3 By-pass Pick-up Controls the up-down movement 59
of the pick-up roller for by-pass
feed.
SOL 4 Guide Plate Opens the guide plate when a 61
paper misfeed occurs around this
area.
SOL 5 Transfer Belt Controls the up-down movement 62
Positioning of the transfer belt unit.
SOL 6 Pressure Arm Presses the paper on the duplex 63
tray against the duplex feed
rollers.
SOL 7 Tandem Lock Locks the left tandem feed tray 97
and separates the right and left
tandem trays.

FSM 2-9 A095/A096/A097

Symbol Name Function Index
No.
SOL 8 1st Pick-up Controls the up-down movement 98
of the pick-up roller in the 1st
feed station.
SOL 9 1st Separation Roller Controls the up-down movement 100
of the separation roller in the 1st
feed station.
SOL10 2nd Pick-up Controls the up-down movement 102
of the pick-up roller in the 2nd
feed station.
SOL11 2nd Separation Controls the up-down movement 103
Roller of the separation roller in the 2nd
feed station.
SOL12 3rd Pick-up Controls the up-down movement 105
of the pick-up roller in the 3rd
feed station.
SOL13 3rd Separation Roller Controls the up-down movement 106
of the separation roller in the 3rd
feed station.

Sensors
S 1 Scanner HP Informs the CPU when the 1st 1
and 2nd scanners are at the
home position.
S 2 Platen Cover Informs the CPU that the platen 2
Position–1 cover is in the up or down
position (related to APS/ARE
function).
S 3 Platen Cover Informs the CPU that the platen 3
Position–2 cover is in the up or down
position to detect if the original
has been removed or not.
S 4 Lens Vertical HP Informs the CPU that the lens is 4
at the full-size position.
S 5 Lens Horizontal HP Informs the CPU that the lens is 5
at the horizontal home position.
S 6 3rd Scanner HP Informs the CPU when the 3rd 6
scanner is at the home position.
S 7 By-Pass Paper End Informs the CPU that there is no 7
paper in the by-pass feed table.

A095/A096/A097 2-10 FSM

Rev. 10/94

Symbol Name Function Index

No.
S 8 Guide Plate Position Informs the CPU if the 8
registration guide plate is closed
or not.
S 9 Jogger HP Detects if the duplex jogger 9
fences are at the home position
or not.

Component
Description
S10 Vertical Transport Detects the leading edge of the 10

Layout &
paper to determine the paper
feed timing of the next sheet.
S11 Duplex Exit Detects the leading edge of the 11
paper to determine the duplex
transport clutch on timing.
S12 Duplex Entrance Detects the leading edge of the 14
Sensor paper to determine the duplex
feed clutch off timing.
S13 Duplex Paper End Detects paper in the duplex tray. 13
S14 Duplex Transport Detects the leading edge of the 12
paper to control the jogger motor
and the positioning solenoid on
timing.
S15 Exit Detects misfeeds. 15
S16 Fusing Exit Detects misfeeds. 16
S17 Paper Guide Detects misfeeds. 17
S18 Auto Image Density Senses the background density 20
of the original.
S19 Original Length–1 Detects original length. 21
S20 Original Length–2 Detects original length. 22
S21 Original Width Detects original width. 23
S22 By-Pass Paper Size Informs the CPU what size paper 26
is in the by-pass feed table.
S23 Toner Density Senses the amount of toner in 27
the black developer.
S24 Registration Detects misfeeds and controls 28
registration clutch off-on timing.
S25 Toner End Detects toner end condition. 30
S26 Auto-Response Returns the display from the 34
screen saver.

FSM 2-11 A095/A096/A097

Rev. 7/94
Symbol Name Function Index
No.
S27 Drum Potential Detects the drum surface 39
potential.
S28 Image Density Detects the density of the ID 41
sensor pattern on the drum.
S29 1st Paper End Informs the CPU when the 1st 68
cassette runs out of paper.
S30 1st Paper Near End Informs the CPU when the 1st 69
cassette is in near end condition.
S31 1st Paper Feed Controls the 1st paper feed 70
clutch off/on timing and the 1st
pick-up solenoid off timing.
S32 2nd Paper Near End Informs the CPU when the 2nd 71
cassette is in near end condition.
S33 1st Lift Detects the correct feed height of 72
the 1st cassette.
S34 2nd Paper End Informs the CPU when the 2nd 73
cassette runs out of paper.
S35 Toner Collection Detects the toner collection 74
Motor motor operation.
S36 2nd Lift Detects the correct feed height of 76
the 2nd cassette.
S37 3rd Lift Detects the correct feed height of 78
the 3rd cassette.
S38 3rd Paper Near End Informs the CPU when the 3rd 79
(A095) cassette is in near end condition.
S39 3rd Paper End Informs the CPU when the 3rd 80
cassette runs out of paper.
S40 3rd Paper Feed Controls the 3rd paper feed 81
clutch off/on timing and the 3rd
pick-up solenoid off timing.
S41 2nd Paper Feed Controls the 2nd paper feed 82
clutch off/on timing and the 2nd
pick-up solenoid off timing.
S42 Base Plate Down Detects when the bottom plate is 85
(A096/A097) completely lowered to stop the
1st lift motor.
S43 Side Fence Informs the CPU when the 86
Positioning tandem tray side fences are
(A096/A097) open.

A095/A096/A097 2-12 FSM

Rev. 7/94
Symbol Name Function Index
No.
S44 Rear Fence Return Informs the CPU when the 87
(A096/A097) tandem tray rear fence is in the
return position.
S45 Rear Fence HP Informs the CPU when the 88
(A096/A097) tandem tray rear fence is in the
home position.

Component
Description
S46 Left Tandem Paper Informs the CPU when the left 89

Layout &
End tandem tray runs out of paper.
(A096/A097)
S47 LCT Near End Detects the paper near end 123
(A096/A097) condition.
S48 Tray Down Detects when the tray is 124
(A096/A097) completely lowered to stop the
LCT motor.
S49 Tray Paper Set Informs the CPU when the paper 125
(A096/A097) is set on the LCT bottom tray.

PCBs
PCB 1 AC Drive Provides AC power to the 108
exposure lamp and fusing lamp.

PCB 2 Main Controls all machine functions. 109

PCB 3 Optic Control Controls all optics components. 110

PCB 4 High Voltage Control Controls the output of both power 111
packs and development bias.
PCB 5 Paper Feed Control Controls all components in the 112
paper bank.
PCB 6 DC Power Supply Provides DC power. 113
Unit
PCB 7 Guidance Controls the guidance display. 120
PCB 8 Operation Panel Controls the LED matrix, and 121
monitors the key matrix.

Lamps
L1 Exposure Applies high intensity light to the 18
original for exposure.
L2 Fusing (2 in A097) Provides heat to the hot roller. 32

FSM 2-13 A095/A096/A097

Rev. 7/94

Symbol Name Function Index

No.
L3 Quenching Neutralizes any charge 37
remaining on the drum surface
after cleaning.
L4 Erase Discharges the drum outside the 38
image area.
L5 Pre-transfer Reduces the charge on the drum 40
surface before transfer.

Power Packs
PP1 Transfer Provides high voltage for the 117
transfer belt and controls the
transfer belt positioning solenoid.
PP2 Charge Provides high voltage for the 119
charge corona wires, and the
grid plate. Controls QL, PTL, and
charge wire cleaner motor
functions.

Others
TS1 Optics Thermoswitch Opens the exposure lamp circuit 19
if the optics unit overheats.
TF1 Fusing Thermofuse Opens the fusing lamp circuit if 33
the fusing unit overheats.
TH1 Fusing Thermistor Senses the temperature of the 24
hot roller.
TH2 Optics Thermistor Monitors the temperature of the 36
optics cavity.
TH3 Drum Thermistor Monitors the temperature of the 41
(Located on the ID OPC drum.
Sensor Ass’y)
H1 Transfer Turns on when the main switch is 31
Anti-Condensation off to prevent moisture from
forming on the transfer belt.
H2 Optics Turns on when the main switch is 35
Anti-Condensation off to prevent moisture from
forming on the optics.
RA1 Main Power Relay Controls main power. 107

A095/A096/A097 2-14 FSM

Rev. 7/94

Symbol Name Function Index

No.
TH1 Fusing Thermistor Senses the temperature of the 24
hot roller.
TH2 Optics Thermistor Monitors the temperature of the 36
optics cavity.
TH3 Drum Thermistor Monitors the temperature of the 41
(Located on the ID OPC drum.
Sensor Ass’y)
H1 Transfer Turns on when the main switch is 31
Anti-Condensation off to prevent moisture from
forming on the transfer belt.
H2 Optics Turns on when the main switch is 35
Anti-Condensation off to prevent moisture from
forming on the optics.
RA1 Main Power Relay Controls main power. 107
CO1 Total Counter Keeps track of the total number 114
of copies made.
NF1 Noise Filter Removes electrical noise. 115
CB1 Circuit Breaker Provides back-up high current 116
protection for the electrical
components.
LA1 Lightening Arrestor Removes current surges from the 118
AC input lines.

FT6665 (A097) copier only (unique items)

Symbol Name Function Index

No.
Motors
M22 AC Drive Cooling Removes heat from around the 141
Fan AC drive unit.
M23 Optic Cooling Fan-2 Removes heat from the optic unit. 142
M24 Duplex Cooling Fan Cools the paper on the duplex 143
tray to reduce the heat around
the drum.

FSM 2-15 FT6645/6655/6665

INSTALLATION
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 Illumination: Less than 1,500 lux (Do not expose to direct
sunlight.)
4. Ventilation: Room air should turn over at least 3 times/hour.)
5. Ambient Dust: Less than 0.15 mg/m3 (4 x 103 Oz/yd3)
6. Room Size: More than 10 m3 (13.4 yd3)
7. If the place of installation is air-conditioned or heated, do not place the

INSTALLATION
machine.
a) where it will be subjected to sudden temperature changes.
b) where it will be directly exposed to cool air from an air conditioner.
c) where it will be directly exposed to heat from a heater.

8. Do not place the machine where it will be exposed to corrosive gasses.

9. Do not install the machine at any location over 2,000 m (6,500 feet)
above sea level.
10. Place the copier on a strong and level base.
11. Do not place the machine where it may be subjected to strong vibrations.

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
NOTE: The machine legs may be screwed up or down in order to level
the machine. Set a carpenter’s level on the exposure glass.

FSM 3-1 A095/A096/A097

1.3 MINIMUM SPACE REQUIREMENTS
Place the copier near the power source, providing clearance as shown:

More than 10 cm (4 inches)

More than More than

(See NOTE *3)
10 cm (4 inches) 10 cm (4 inches)
(See NOTE *2) (See NOTE *1)
Your machine

More than 90 cm

NOTE: *1. If the LCT is not installed, the distance between the wall and
the edge of the by-pass feed table must be more than 30 cm.
*2. If the A374 sorter stapler is installed, the distance must be
more than 20 cm (8 inches).
*3. Copier only: 128.0 cm; 50.4" (with LCT 134.7cm, 53")
Copier + A374 S/S: 110.0 cm; 43.4" (with LCT 142.2cm, 56")
Copier + A377 S/S: 125.6 cm; 49.4" (with LCT 156.8cm, 61.7")
Copier + Finisher: 136.1cm; 53.6" (with LCT 167.3cm, 65.9")

A095/A096/A097 3-2 FSM

1.4 POWER REQUIREMENTS
1. Input voltage level: 120 V/60 Hz: More than 20 A
220 ~ 240 V, 50/60 Hz: More than 10 A
2. Permissible voltage fluctuation: 10%
3. Permissible extension cord:
At least 300 V/30 A capacity and less than 5 m (16.4 feet) long.
NOTE: a) be sure to ground the machine. (Do not ground it to a gas pipe.)
b) Make sure the plug is firmly inserted in the outlet.
c) Avoid multi-wiring.

4. Do not set anything on the power cord.

INSTALLATION

FSM 3-3 A095/A096/A097

Rev. 1/20/94
2. COPIER INSTALLATION
2.1 ACCESSORY CHECK
Check the quantity and condition of the accessories in the box according to
the following list:
Description Q’ty
1. Operating Instructions (Except –27 machine)...............................1
2. User Survey Card (–17 machine only)..........................................1
3. Envelope-NECR (–17 machine only) ............................................1
4. NECR (–17, –27, –29 machines only) ..........................................1
5. Sensor Cover ................................................................................1
6. Flat Head Screw 4 x 6...................................................................1
7. Leveling Foot.................................................................................4

20A 15A

NOTE: This copier requires a 20 Amp service with a USA 20A plug
socket. The shape of the 20A socket is different from that of the
standard 15A. The two are not interchangeable. If there is no
20A socket at the customer location, the electrical supply line
must be changed as well as the socket. Contact the local electric
company for more information.

A095/A096/A097 3-4 FSM

2.2 COPIER INSTALLATION PROCEDURE

NOTE: Since the installation procedure is not packed with the copier as
an accessory, always bring this manual with you.

INSTALLATION
[B]
[A]

CAUTION: When installing the copier, make sure that the copier is
unplugged.

NOTE: Insert the leveling shoes [A] under the leveling feet [B], and level the
machine before starting the installation. (The leveling feet [B] can be
screwed up or down.)
1. Remove the tape strips.

FSM 3-5 A095/A096/A097

Rev. 1/20/94
[A] [B]

[D]

[C]

2. Open the front doors.

3. Remove the tape strips.
4. Remove the scanner clamp [A] (1 screw) and install the cap [B] taped to
the paper exit bracket.
5. Remove the transfer belt lock plate [C] (1 screw).
6. Remove tape and move toner cartridge holder out to expose the
cleaning unit lock pin [D].
7. Turn about 180° then remove the cleaning unit lock pin [D].
8. Remove the retaining tape [A] from the fusing exit guide.

[A]

A095/A096/A097 3-6 FSM

[X]

[C] [A] [E]

[A] [B]

INSTALLATION
[F]
[G]
[D]

[K] [F]

[H]
[I] [J]

7. Remove the shutter cover [A] by releasing the hook [B].

8. Pivot Lever [X] forward.
9. Remove the shutter inner cover [C] (1 screw).
10. Open the toner bottle holder [D].
NOTE: To open the toner bottle completely, while lowering the shutter
lever [E], push the bracket [F] to the right.
11. Close the toner hopper cap [G].
12. Remove the screw [H] fixing the drum stay [I].
13. Remove the drum stay knob [J].
14. Remove drum stay [K].

FSM 3-7 A095/A096/A097

[B]

[A]

[E]

[F]

[C]

[D]

15. Disconnect two connectors [A].

16. Pull out the development unit [B].
NOTE: 1. To prevent drum scratches, push the development unit to the
right while pulling it out.
2. Place the development unit on several sheets of paper [C] to
prevent foreign matter from being attracted to the sleeve rollers.
3. When pulling out the development unit, do not pull the knob [D].
17. Remove two screws [E] fixing the toner hopper [F].
18. Turn the toner hopper 90 degree, then, move it up to remove it from the
development unit.

A095/A096/A097 3-8 FSM

[A]

[C]

[B]

INSTALLATION
[H]

[G]

[D]

[E] [F]

19. Evenly pour in one pack of developer [A] while turning the knob [B].
20. Install the toner hopper [C] to the development unit (2 screws).
21. Install the development unit to the machine.
22. Connect two connectors [D].
23. Install the drum stay [E] with the drum stay knob [F] and one screw [G].
NOTE: When installing the drum stay, be careful not to pinch the
harness and keep the harness away from the gear.
24. Open the toner hopper cap [H].

FSM 3-9 A095/A096/A097

[A]

[C]

[B]

24. Install the shutter inner cover [A] (1 screw).

25. Push the lever [B], to the full rear position and set the shutter cover [C].
26. Set a toner bottle by following the instructions on the decal.
NOTE: Before plugging in the power cord, install the guidance ROMs.
(–26, –27 machines) (See page 3-12)
27. Plug in the power cord, then turn on the main switch. The machine
automatically enter the process control data initial setting mode.
NOTE: Do not make any copy until completing developer initial setting.
Do not turn off the main switch during the process control data initial
setting mode.
28. Add paper to at least one tray.

A095/A096/A097 3-10 FSM

Rev. 5/93
30. Enter SP mode as follows:
1) Press the clear modes key.
2) Enter "107".
3) Press the clear/stop key for more than 3 seconds.

1 0 7 C

31. Press the "SP Adjustment"

key [A]. [D]

INSTALLATION
[A]

[C]
32. Press the developer initial
setting"Start" key [B].
[B]
Note 1: When performing the
developer initial setting, do
not make any copies until
completing developer (TD
sensor) initial setting.

Note 2: Do not forget to perform the developer (TD sensor) initial setting
when replacing the developer. Also, when the TD sensor is
replaced, install new developer and perform developer initial setting.
Note 3: Developer initial setting stops automatically.
33. Press the "Index" key [C].
34. Press the "Quit" key [D] to exit SP mode.
NOTE: If the developer initial setting is not completed, you cannot exit
the SP mode by pressing the "Quit" key. If this occurs, turn the
main switch off and on then repeat steps 30 to 34 again. If the
result is the same, see the troubleshooting section "SC352"
(Page 6- 9).
35. Check copy quality and machine operation.

FSM 3-11 A095/A096/A097

Rev. 7/94
2.3 GUIDANCE ROM INSTALLATION

[A]

[C]
[B]

[E]

[D]

1. If necessary, replace the three guidance ROMs on the operation panel

PCB with the optional guidance ROMs as follows:
1) Remove the pin [A] then lower the left front door [B].
2) Remove the left inner cover [C] (4 screws).
3) Remove three screws [D].
4) Remove the two screws [E] securing the protective earth ground wires.

A095/A096/A097 3-12 FSM

Rev. 7/94
[H]
[G]

[F]

INSTALLATION
[L]

[I]

[K]
[J]

5) Insert the screw driver from the hole [F] and push the operation panel
[G] up.
6) Disconnect the connector [H].
7) Replace the guidance ROMs (IC111 [I], IC112 [J], IC113 [K]) on the
operation panel PCB [L].
8) Re-install the operation panel, the left inner cover and the left front
door.

2. After installing the new guidance ROMs, plug in the power cord and turn
on the main switch then perform the "Touch Panel Display Position
Adjustment". See page 5-129 for detailed procedure.

FSM 3-13 A095/A096/A097

2.4 PLATEN COVER (OPTION) INSTALLATION

[B]

[F]

[D]
[H] [C]

[G]
[A]

[H] [E]

Install the optional platen cover as follows:

1. Install the sensor ass’y [A] which is an accessory of the platen cover [B]
as follows:
1) Connect the red connector [C] to the rear sensor [D].
2) Connect the white connector [E] to the front sensor [F].
3) Secure the sensor assembly with a screw [G].

2. Install the platen cover hooks [H].

3. Install the platen cover [B].

A095/A096/A097 3-14 FSM

2.5 PAPER SIZE CHANGE

[C]

[B]

INSTALLATION
[B]

[A]

At the factory, all paper cassettes (1st, 2nd and 3rd) are set as A4 sideways.
According to the customer’s request, change the paper size as follows.

2.5.1 550 Sheets Paper Tray (1st and 3rd feed stations for A095 copier)
1. Draw out the paper feed tray [A].
2. Change the position of the front and the rear side fences [B] (2 screws
each) and end fence [C] (one screw) according to the paper size.
3. Stick a size decal on the tray.

FSM 3-15 A095/A096/A097

4. Enter SP mode as follows:
1) Press the clear mode key.
2) Enter "107".
3) Press the clear/stop key more than 3 seconds.

1 0 7 C

5. Press the "SP Special Feature" [D]

key [A].

[A]

6. Press the "Next" key [B] 4 times to

select the paper tray size setting [B] [C]
mode (page 5) and press the
appropriate paper size key of the
1st or the 3rd feed station.

7. Press the "Index" key [C].

8. Press the "Quit" key [D] to exit SP mode.
9. Check copy quality and machine operation.

A095/A096/A097 3-16 FSM

Rev. 7/94
2.5.2 1500 Sheet Paper Tray (3rd feed station for A096/A097 copiers)

[B]

[C]

INSTALLATION
[A]

1. Draw out the third feed tray [A].

2. Change the position of the front and the rear side fences [B] (1 screw
each) and the end fence [C] (one screw) according to the paper size.
3. Perform steps 3 to 9 from the previous page.

FSM 3-17 A095/A096/A097

2.6 KEY COUNTER HOLDER INSTALLATION (OPTION)

[C]

[A]

[B] [E] [D]

NOTE: Key counter holder set is available as a service part.

1. Remove the two plastic caps [A] and [B] on the right upper cover of the
copier.
2. Replace the short-circuit connector [C] with the connector of the
accessory harness [D].
3. Install the stepped screw [E].

A095/A096/A097 3-18 FSM

Rev. 5/94

[E] [H]

INSTALLATION
[G]

[F]

4. Hold the fixing plates [A] on the inside of the key counter bracket [B] and
insert the key counter holder [C].
5. Fix the key counter holder [C] to the bracket [B] (2 screws).
6. Install the key counter cover [D] (2 screws).
7. Connect the connector [E] of the key counter holder.
8. Hook the key counter holder assembly [F] to the stepped screw [G].
9. Secure the key counter holder assembly [F] with a screw [H].
NOTE: If your key counter is a Ricoh brand, install the mylar [I]
(P/N A509 1064) as shown.

FSM 3-19 A095/A096/A097

2.7 IMAGE DENSITY ADJUSTMENT
The copy image density is already adjusted to the standard level at the
factory. If a customer requests to have the image density adjusted, it can be
done through the User Tool mode.
1. Enter the User Tool mode as follows:
1) Press the clear mode key.
2) Press the clear/stop key more than 3 seconds.

2. Press the "Set operation modes" key [A].

[A]

3. Press the "Next" key once [B].

[B]

A095/A096/A097 3-20 FSM

4. Select appropriate Image Density
level (5 steps) adjustment:
1) Press appropriate ID level [C]
key [A]. [B]
2) Press the enter key [B].
[A]

5. Press the "Menu" key [C].

6. Press the "Exit" key [D] to exit User

INSTALLATION
Tools mode. [D]

7. Check copy quality.

FSM 3-21 A095/A096/A097

SERVICE TABLES
1. SERVICE REMARKS
1.1 HANDLING THE DRUM
The organic photoconductor drum is comparatively 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 fingers or becomes dirty, wipe with a dry cloth or clean
with wet cotton. Wipe with a dry cloth after cleaning with wet cotton.
3. Never use alcohol to clean the drum; alcohol dissolves 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 drum layer is thin and is easily
damaged.
6. Never expose the drum to corrosive gases such as ammonia gas.
7. Always keep the drum in its protective sheet when out of the copier. Also
always close the protective shutter on the drum unit when keeping the

Service Tables
drum unit out of the copier. Doing so avoids exposing the drum to bright
light or direct sunlight. This will protect the drum from light fatigue.
8. Process control data initial setting ( 1 SP Adjustment: PAGE 1) must
be performed when a new drum is installed.

FSM 4-1 A095/A096/A097

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 switch is turned on. If the drum unit
is loose, poor contact of the drum connectors may cause electrical noise,
resulting in unexpected malfunctions (RAM data change is the worst
case).
2. To prevent drum scratches, remove the development unit before
removing the drum unit.

1.3 CHARGE CORONA

1. Clean the corona wires with a dry cloth. Do not use sandpaper or
solvent.
2. Clean the charge corona casing with water first to remove NOX. Then
clean it with alcohol if any toner still remains on the casing.
3. Clean the end blocks with a blower brush first to remove toner and paper
dust. Then clean it with alcohol if any toner still remains on it.
4. Do not touch the corona wires with oily bare hands. Oil stains may cause
white bands on copies.
5. Make sure that the corona wires are correctly positioned between the
cleaner pads and that there is no foreign material (iron filings, etc.) on the
casing.
6. When installing new corona wires, do not bend or scratch the wire
surface to avoid any uneven charge. Also be sure that the corona wires
are correctly positioned in the end blocks. (See charge corona wire
replacement.)
7. Clean the charge grid plate with a blower bush (not with a cloth).
8. Do not touch the charge grid plate with oily bare hands. Also, do not
bend the charge grid plate or make any dent on it. Doing so may cause
an uneven charge.

A095/A096/A097 4-2 FSM

1.4 OPTICS
1. When installing the exposure glass, make sure that the mark (red for the
A095 and white for the A096) on the edge of the glass faces up. This
side has received a special treatment to be smoother and generate less
static electricity.
2. When moving the 1st or 2nd scanners, always hold them at the center.
Move them slowly, carefully, and gently.
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) VD, ADS and VL patterns

5. To clean the mirrors and lens, use only a clean soft cloth dampened with
alcohol or water.
6. Do not turn the vertical lamp position adjusting cam. Adjusting the

Service Tables
vertical lamp position is very difficult because the filament cannot be
seen clearly as the lamp is frosted.
7. The mirror surface with the reflective coating must face the light path.
The spring plates must contact the reverse side of the mirror (the side
without the reflective coating).
8. Because the toner shielding filter is coated with an anti-static solution
(which is removed when wiped with water or alcohol) clean the toner
shielding filter very gently to prevent generating static electricity, and
wipe with dry cloth.

1.5 ERASE LAMP

1. A narrower lead edge erase 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 unit surface.
3. Use only a dry cloth to clean the potential sensor.

FSM 4-3 A095/A096/A097

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.) from being attracted to the development roller and getting inside the
unit.
3. Be careful not to bend terminals on the rear side.
4. Clean the drive gears after removing the used developer.
5. Never load different types of developer or toner into the development
unit. Doing so will cause poor copy image and toner scattering inside the
copier.
6. Developer initial setting is necessary when new developer is loaded.
Do not perform the developer initial setting with used developer.
Do not make any copy before initial setting.
7. When removing the development unit, push it to the right to prevent the
OPC drum from being scratched by part of the development unit.
8. The doctor gap and the development rollers position must not be
adjusted in the field as they are precisely adjusted at the factory using
special tools. Do not loosen any screws with white paint.
9. Before pulling out the development unit, disconnect two connectors.
10. When inserting out the development unit, do not pull the knob.
11. When setting the development unit in the machine, do not forget to
replace the two connectors.
1.7 TRANSFER BELT UNIT
1. Do not touch the transfer belt with oily bare hands.
2. When servicing the transfer belt cleaning unit, be careful not to damage
the edge of the cleaning blade.
3. Apply setting powder or toner to the new cleaning blade.

1.8 CLEANING SECTION

1. When serviceing the cleaning section, be careful not to damage the edge
of the cleaning blade.
2. Do not touch the cleaning brush with vare hands.
3. Before disassembling the cleaning section, place a sheet of paper under
it to catch any toner falling from the section.

A095/A096/A097 4-4 FSM

4. Empty the used toner collection bottle at every PM.
5. Apply setting powder to the new cleaning blade.

1.9 PRE-TRANSFER LAMP

1. After cleaning the pre-transfer lamp filter, rub it lightly with your finger to
discharge any static electricity on the filter.

1.10 PAPER FEED

1. Do not touch the pick-up, feed, separation rollers and the friction pads
with oily bare hands.
2. The side fences and the rear fence of the paper trays should be
positioned correctly to align with the actual paper size. Otherwise, paper
misfeeds may occur.
3. Be careful when reinstalling the paper feed (pick-up, feed, separation)
rollers in the paper tray unit. They are not interchangeable with the feed
rollers of the by-pass feed tray and 3.5 K LCT because the feeding
direction is different.

Service Tables
4. When actuating the front door safety switch to check the machine
operation while the front doors are open also actuate the lower front door
safety switch. Otherwise, the paper feed motor does not activate,
causing SC501.

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 lamp with bare hands.
3. Make sure that the fusing lamp is positioned correctly (the yellow
connector must be at the rear) and that it does not touch the inner
surface of the hot roller.
4. Level the oil supply roller while it is stored, otherwise the silicone oil in
the oil supply roller comes out from the lower part.

FSM 4-5 A095/A096/A097

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 values.

2.1.1 Service Program Access Procedure

1. Press the clear modes key.
2. Enter "107".
3. Press the clear/stop key for more than 3 seconds until the service
program index menu appears on the touch panel display.

1 0 7 C

4. Touch a number [A] on the [D]

display to access the desired
function.
This copier has 9 service
program modes
(mode 5 is not used). [A]
Only 5 service program modes
are visible on the touch panel [C]
display at one time.
Use the down key [B] or the up [B]
key [C] to see other service
program mode menus.

2.1.2 To Exit SP Mode

1. Touch the Quit key [D].

A095/A096/A097 4-6 FSM

2.1.3 To Return to the Index Menu
1. Return to the index menu by
touching Index [A]
[C] [B] [A]
on the display.

[D]
[F]

[E]
2.1.4 Change the Menu Screen
1. To move to the next page, touch Next [B].

2. To move to the previous page, touch Prev. [C].

NOTE: For the adjustments for which the data is entered by using,

Service Tables
[D] the default data is "00".

2.1.5 Access to "Copy in SP" Mode

1. Press Copy in SP [F] to
access "Copy in SP" mode. LCD
displays as shown at right. [G]

2. Select the appropriate copy

mode and make trial copies.
3. Return to the SP mode by
pressing SP mode [G].

FSM 4-7 A095/A096/A097

2.2 SERVICE PROGRAM MODE TABLE
1 SP ADJUSTMENT

PAGE 1

❶
❷
❸
❹

Item Function Note

❶ Both the TD sensor toner supply target With new developer, do not make any
data (VREF) and the TD sensor gain copy before performing the developer
data are set automatically by using initial setting.
new developer.
This mode is required when new
developer is set or the TD sensor is
replaced.

❷ Starts the process control data initial Perform this program when the
setting. following parts are replaced (or
cleaned).
Drum potential sensor / Exposure
lamp / OPC drum /
Main charge wire and casing /
Mirrors / Lamps around the OPC drum /
Charge P.P./ RAM etc.

❸ Increases the period to sufficiently heat Perform this only if poor fusing occurs
the pressure roller at power on. just after the power is turned on.
Default: 5 min

❹ Adjusts fusing temperature. (1°C/ step) Increase only when thick paper is used
Procedure: and poor fusing occurs. Default: 185 °C
1) Touch Adjust .
2) Enter the appropriate number by
using the number keys.
3) Press the enter key.

A095/A096/A097 4-8 FSM

Rev. 7/94

PAGE 2

❶ ⑤
❷
①
⑥
②
③
④
⑦
(A095/A096 copiers)
Item Function Note

❶ Enables or disables automatic charge Select OFF only when a cleaning

wire cleaning mechanism. Default: ON mechanism malfunction occur.

❷ Changes the paper feed clutch on Refer to 6.6 Paper Feed Timing
timing to adjust the paper buckle at the Adjustment" in section 5.
registration roller. (1 mm/step) ① First paper feed clutch ON timing
at the first copy
② First paper feed clutch ON timing
after the second copy.

Service Tables
③ 2nd paper feed clutch ON timing.
④ 3rd paper feed clutch ON timing.
⑤ By-pass feed clutch ON timing.
⑥ Duplex feed clutch ON timing.
⑦ LCT feed clutch ON timing.

(A097 copier)
Item Function Note

❶ Enables or disables automatic charge Select OFF only when a cleaning

wire cleaning mechanism. Default: ON mechanism malfunction occurs.

❷ Changes the paper feed clutch on Refer to 6.6 Paper Feed Timing
timing to adjust the paper buckle at the Adjustment" in section 5.
registration roller. (1 mm/step) ① Not used * (See below)
② First paper feed clutch ON timing
③ 2nd paper feed clutch ON timing.
④ 3rd paper feed clutch ON timing.
⑤ By-pass feed clutch ON timing.
⑥ Duplex feed clutch ON timing.
⑦ LCT feed clutch ON timing.
* You can change the value by + or - key, however, it does not affect the
paper feed timing.

FSM 4-9 A095/A096/A097

Rev. 7/94
1 SP ADJUSTMENT
PAGE 3 PAGE 4

❶ ❺
❷ ❻

❸
❹
❼

Item Function Note

❶ Changes the ON timing of the Adjustment standard: 0 ± 2 mm

registration clutch. (0.5 mm/step)

❷ Changes the OFF timing of the erase Adjustment standard: 3.5 ± 2.5 mm
lamp to adjust the leading edge erase
margin. (0.5 mm/step)

❸ Adjusts magnification in the paper feed Perform this adjustment when the optic
direction by adjusting the scanner control PCB is replaced.
motor speed. (0.1%/step) Adjustment standard: 100 ± 1%

❹ Adjusts magnification perpendicular to Perform this adjustment when the optic

the direction of the paper feed. The control PCB is replaced.
lens position in the full size mode is Adjustment standard: 100 ± 1%
changed. (0.1%/step)

❺ Enables or disables the 5 mm width Default: No

side edge erase.

❻ Adjusts the lens horizontal stop Refer to 9.2 Side-To-Side Registration

(A095/ position for each paper feed section. Adjustment" in Section 5.
A096) (0.1 mm/step)

❻ Adjusts the lens horizontal stop Only for A097 copier with RDH and
(A097) position for each paper feed section. Finisher, the SP data for each feed
(0.1 mm/step) station should be the same as that for
Duplex tray. If not, the copy speed
when in alternate paper feed mode (1
sided original to 2 sided copy mode)
will be decreased. *

❼ Adjusts the lens horizontal stop

position to compensate for variations
of the side to side original position.
* Refer to 8.6.2 Side-To-Side Registration Adjustment "-Rough Adjustment-" in
Section 5. For other cases any SP data can be input. Refer to 8.6.2 Side-To-Side
Registration Adjustment in Section 5.

A095/A096/A097 4-10 FSM

1 SP ADJUSTMENT
PAGE 5 PAGE 6

❶ ❺
❷ ❻
❸ ❼
❹

Item Function Note

❶ Adjusts the lens position to correct Input only the data number marked on
magnification in enlarge/reduction the lens.
modes.

❷ Adjusts the 3rd scanner home position

to correct the focus.

❸ Factory use only Do not change the data.

Service Tables
❹ Adjusts the ADS sensor output while This mode is also performed during the
scanning the ADS pattern to 2.7 ± 0.1 V process control data initial setting.

❺ Adjusts the VSG to 4.0 ± 0.2 V. This mode is also performed during the
process control data initial setting.

❻ Adjusts the original stop position 1. Refer to 6.9.1 one sided original
against the original side scale in mode in Section 7.
one-sided original mode (0.5 mm/step).

❼ Adjusts the original stop position 2.. Refer to 6.9.2 two sided original
against the original side scale in mode in Section 7.
two-sided original mode (0.5 mm/step).

FSM 4-11 A095/A096/A097

Rev. 4/15/94
1 SP ADJUSTMENT
PAGE 7 PAGE 8

❶
❺
❷ ❻
❼
❸ ❽
❹ ❾

Item Function Note

❶ Selects toner supply mode. Select "Auto Mode" in the field.

(See the process control section for
details of each supply mode.)
Default: Auto Mode

❷ Factory Use only Select "N" in the field.

❸ Changes the toner supply ratio in fixed Be careful, there is no overtoning

toner supply mode. Default: 4% protective system.

❹ Enables and disables the auto process Normally select "Set". Select "Reset"
control (VR, VL, VD corrections). only to confirm if the cause of the
(See the process control section for problem is related to process control or
details.) Default: Set not.

❺ Selects the grid bias voltage when Enter the data by using the number
auto process control is disabled or keys, then touch "Enter".
RAM is cleared. (1 V/step)
Default: 870 V

❻ Selects the development bias voltage Enter the data by using the number
when auto process control is disabled keys, then touch "Enter".
or RAM is cleared. (1 V/step)
Default: 220 V

❼ Factory Use only Do not change the data in the field.

❽ Factory Use only Do not change the data in the field.

❾ Factory use only. Do not change the data in the field.

NOTE: Selecting item 4 above will enable items 5 and 6 to be used to

troubleshoot or isolate problems related to process control. See
also item 1, page 4-13.

A095/A096/A097 4-12 FSM

1 SP ADJUSTMENT
PAGE 9

❶
❷
❸
①
②

Item Function Note

❶ Selects the exposure lamp voltage Enter the data by using the number
when auto process control is disabled keys, then touch Adjust .
or RAM is cleared. (0.5 V/step)
Default: 65.0 V

❷ Adjusts the transfer current. Standard Data: 50 mA

(1µA/step) Enter the data by using the number
Default: 50 µA keys, then touch Adjust .

Service Tables
❸ Initializes the by-pass paper size Procedure:
sensor. 1. Set the by-pass table side fence to
the A4/81/2 x 11 position, then
touch the Enter key ①.
2. Set the by-pass table side fence to
the A6/41/4 x 51/2 position, then
touch the Enter key ② .
Perform this mode when the by-pass
paper size sensor is replaced.

NOTE: Selecting SP adjust pg.7, #4 will enable item 1 above to be used

for troubleshooting or isolating problems related to process
control.

FSM 4-13 A095/A096/A097

Rev. 5/94
1 SP ADJUSTMENT
PAGE 10 A4/A3 VERSION PAGE 11 LT/DLT VERSION

Item Function Note

❶ Adjusts the duplex jogger fence Press to decrease the distance

position for each paper size. in-between the side fences.
(0.3 mm/step) (0.3mm/Step)
Press to increase the distance
in-between the side fences.
(0.3mm/Step)
Procedure:
1. Enter SP mode then enter copy in SP.
2. Feed a sheet of papter to the duplex
tray.
3. Take out the duplex unit then check the
stacked paper and jogger fence
position.
4. Return to SP mode (touch SP mode key).
5. Touch + or - keys to adjust
the fogger fence position so that the
distance between the fences is
1mm wider then the paper width.
6. Repeat step 1 to 5 until adjustment completes.
NOTE: Enter copy in SP after changing
data to correctly store the changed data
in memory. If not, sometimes the data
cannot be stored in memory.

A095/A096/A097 4-14 FSM

1 SP ADJUSTMENT
PAGE 12

❶
①
②
NOTE: PAGE 15 is for factory use
only. PAGE 16 is an extra
page, it is not used.

PAGE 13 PAGE 14
A4/A3 VERSION T/DLT VERSION

❷
❸ ❸

Service Tables
Item Function Note

❶ Adjusts the staple position. This mode affects only

the A377 Sorter Stapler
① Adjusts the vertical ① (horizontal and vertical)
staple position.
and the A379 Finisher
② Adjusts the horizontal (horizontal only).
staple position.
(0.5 mm/step)
②

❷ Changes the duplex positioning roller down timing for

both A4/A3 and LT/DLT version machines.

❸ Changes the duplex positioning roller up timing to Adjusts the timing so that
adjust the paper buckle at the separation roller. the paper leading edge
(5 ms/step) just touches the
separation belt without
any buckle.

FSM 4-15 A095/A096/A097

2 SP TEST MODE
PAGE 1 PAGE 2

❶ ❺
❷
❸
❹

Item Function Note

❶ Operates the copier without feeding Place sheets of white paper (A3 or 11"
paper. x 17") on the exposure glass.

❷ Operates the copier without feeding Do not operate the machine in this
paper or turning on the exposure lamp. mode for a long time because a lot of
toner is spent.

❸ Disables jam detection. This mode is only effective in the "Copy

(Not effective for peripherals) in SP" mode.

❹ Indicates the paper width detected by

the by-pass paper size sensor.

❺ Rotates the main and development Toner is supplied under the following
motors and turns on the toner supply conditions.
clutch to supply toner in the 1. Toner supply ratio: 25%
development unit. 2. Repeats 0.5 sec ON and 1.5 sec,
T.D. sensor toner supply target data OFF.
(VREF) and detected data (VT) is 3. Continues 30 sec.
indicated. Check the image after this SP mode
is completed.

A095/A096/A097 4-16 FSM

Rev. 4/15/94
2 SP TEST MODE
PAGE 3 PAGE 4

❶ ❹
❺
❷
①
❸
②
③
Item Function Note

❶ Use to check if the original size Status 0 ----- de-activated

sensors are correctly activated and Status 1 ----- activated
de-activated.

❷ Use to check if the sensors or switches Status 0 ----- de-activated

are correctly activated and Status 1 ----- activated
de-activated.
Access this mode as follows:

Service Tables
1. Touch the input mode key ①.
2. Enter the sensor/switch/signal
number by using the number keys This mode cannot be used with the
on the operation panel. (Refer to the (ST24 Sorter/Stapler)
input check mode on page 4-36)
3. Touch the enter key ③.

❸ Use to confirm the proper function of Touch ON to activate and touch

the copier electrical components
OFF to de-activate the electrical
Access this mode as follows:
component
1. Touch the Output mode key ② .
2. Enter the electrical component
number by using the number keys
on the operation panel (Refer to the
output check mode on page This mode cannot be used with the
4-42). ST24.
3. Press the enter key ③.

❹ Operates the DF without the copier Procedure:

operation. 1. Set originals on the table.
2. Touch Start .

❺ Operates the sorter stapler (A374 and The sorter operates as if 3 copies are
A377) or A379 finisher without copier made from five originals in sort and
operation. staple mode. No stapling is actually
made.

FSM 4-17 A095/A096/A097

2 SP TEST MODE
PAGE 5

Item Function Note

❶ Operates the toner collection drive After touching the Start key, the
mechanism. toner collection motor turns on for 1
minute.

A095/A096/A097 4-18 FSM

Rev. 4/15/94

3 DATA OUT MODE

PAGE 1 PAGE 2

❶
❷ ❻
❸
❼
❹
❺ ❽

Item Function Note

❶ Indicates the drum potential sensor Standard data: 0.1 ~ 0.7 V

output when –100 V is applied to the
OPC drum.

❷ Indicates the drum potential sensor Standard data: 2.7 V ~ 4.2 V

output when –800 V is applied to the
OPC drum.

❸ Standard data: VR +770 ± 20 V

Service Tables
Indicates the drum potential when
detecting the VD pattern.

❹ Indicates the drum potential when Standard data: VR +140 ± 20V

detecting the VL pattern.

❺ Indicates the drum potential when Standard data: 0 ~ 200 V

detecting the bare drum surface.

❻ Indicates the charge grid bias voltage Works only when auto process control
decided during process control data is enabled. ( 1 SP Adjustment –
initial setting. PAGE 7)
Standard data: 870 ~ 1,200 V

❼ Indicates the development bias voltage Works only when auto process control
decided during process control data is enabled. ( 1 SP Adjustment –
initial setting. PAGE 7)
Standard data: VR -220 V

❽ Indicates the ID sensor bias voltage Works only when auto process control
decided during process control data is enabled. ( 1 SP Adjustment –
initial setting. PAGE 7)
Standard data: 300 V ~ 400 V

NOTE: ❸ ~ ❺ are absolute value.

FSM 4-19 A095/A096/A097

3 DATA OUT MODE
PAGE 3

❶
❷
❸

Item Function Note

❶ Indicates the exposure lamp voltage Works only when the auto process
(ID Level 4) decided during process control is enabled ( 1 SP
control data initial setting. Adjustment - PAGE 7.)
Standard data: 50 ~ 80 V

❷ Indicates the toner supply level by

image area ratio on an original surface.
This data changes at every copy
through fuzzy control.

❸ Indicates the TD sensor output: Standard data: 0.5 ~ 4.0 V

VT: Current detected data
Initial: TD sensor output at last process
control data initial setting.
Previous: Previous detected data during
ID sensor compensation.
VTP: Last detected data during ID
sensor compensation.
VREF: Toner supply level target
data.

❹ Indicates the ID sensor output VSGP is not used for auto image
VSGP: ID sensor output while density control.
detecting the bare drum surface (with
dev. bias and development roller Abnormal condition:
rotation) VSGP < 2.5 V
VSP: ID sensor output while detecting VSP > 2.5 V
the ID sensor pattern image VSG < 2.5 V
VSG: ID sensor output while detecting
the bare drum surface (without
development bias and without
development roller rotation)

A095/A096/A097 4-20 FSM

3 DATA OUT MODE
PAGE 4

❶
❷

❸
❹
❺

Item Function Note

❶ Indicates the drum potential while Standard data: 600 ~ 700 V

detecting ID sensor pattern
(grid voltage = – 700 V)

❷ Indicates the ADS sensor output at Standard data: 2.7 ± 0.1 V

every scan. Present: Output at last detection.
Initial: Output at ID sensor initial
setting.

Service Tables
❸ Indicates the fusing temperature based Standard data: Around 185°C
on the fusing thermistor output.

❹ Indicates the drum temperature based

on the drum thermistor output.

❺ Indicates the optics temperature based

on the optics thermistor output.

FSM 4-21 A095/A096/A097

4 SP SPECIAL FEATURES
PAGE 1

❶
❷

Item Function Setting Default

❶ Selects copy count up or Set Count up

down. Reset
Reset Count down

❷ Counts twice when an A3 Set Count twice

or 11" x 17" copy is made. Reset
Reset Count once

A095/A096/A097 4-22 FSM

Rev. 4/15/94
PAGE 2

[B]
❶
❷ [A]

Item Function Setting Default

❶ Enables user code mode. Set Enable

* See the NOTE below. Reset
Reset Disable

❷ Enables the PM alarm. Set Enable

Service Tables
Reset
Reset Disable

❸ Selects the PM alarm 120 K

interval after counter
clear ( 9 PM Counter
Clear - PAGE 1)

NOTE: To enable user code mode, perform the following procedure.

CAUTION: When Set is selected, at least one user code should be

entered.

1. Register the user code by using user tool No.8.

2. Enter SP mode then enable the user code mode by selecting Set .

3. Turn off the main switch.

4. Remove the plastic cap [A] on the right upper cover.
5. Disconnect the key counter short-circuit connector [B].
6. Return the plastic cap [A].
7. Turn on the main switch and check the operation.

FSM 4-23 A095/A096/A097

Rev. 4/15/94
4 SP SPECIAL FEATURES
PAGE 3

❶
❷
❸
❹

Item Function Setting Default

❶ Enables automatic sort Set

mode selection when 2 or Set Enable
more is entered in the
copy counter and an
original is set on the DJF Reset Disable
feed tray.

❷ Enables automatic Set

feed-out of the last copy Set Enable
on the duplex tray without
copying when an odd
number of originals is set Reset Disable
on the DJF feed tray.

❸ Cancels the maximum

copy quantity limit (50) in Not used
staple mode.

❹ Cancels the maximum

copy quantity limit in sort Not used
mode (50) and in stack
mode (40).

A095/A096/A097 4-24 FSM

Rev. 4/15/94
4 SP SPECIAL FEATURES
PAGE 4

❶
❷

❸
①

Item Function Setting Default

❶ Enables automatic Set Enable Reset

access to the
border/center erase
mode in platen cover Reset Disable
mode.

❷ Enables automatic
selection of a right margin Enable

Service Tables
Set
(5 mm, 0.2") for the
duplex back side when
making 2 sided copies Reset Disable
Set
from 1 sided originals.

❸ Limits user access to

User Tools No. 8, 9, 10,
11 to only those who
know the access code.
Procedure:
1. Touch the 0000 Key. 0000
2. Input the access code
with the number keys.
3. Touch the enter key ➀.
*See the caution below.

CAUTION: After enabling this mode, be sure to instruct the key

operator not to forget the access code.

FSM 4-25 A095/A096/A097

4 SP SPECIAL FEATURES
PAGE 5, 6

❶ ❶

PAGE 7

Item Function Note

❶ Selects the paper size of each paper 1. Default is A4 or 81/2 x 11

feed station. sideways.
Refer to section 3 for details of the
paper size change procedure.

❷ Holds the service center telephone Entering procedure:

number. This telephone number is 1. Touch the
indicated on the LCD with the SC 2. Enter the phone number by
number when a problem occurs. pressing the number keys.
❸ Holds the copier’s serial number. (Touch to enter the
hyphen)
3. Touch # .

A095/A096/A097 4-26 FSM

4 SP SPECIAL FEATURES
PAGE 8 PAGE 9

❶ ❸
❷

Item Function Setting Default

❶ Selects the staple mode for Set Enable Reset

the 1st job when the staple
mode is selected for the 2nd
job in the pre-set mode. Reset Disable

❷ The original size detection Reset

Service Tables
system for this model cannot
distinguish between A4 and Set Enable
81/2 x 11. This mode enables
recognition of A4 and 81/2 x
11originals as A4 size for the
A4/A3 version as 81/2 x 11 for
the LT/DLT version. Reset Disable

❸ Indicates the part number,

with ROM suffixes, on each
PCB. *See NOTE below.

NOTE: Only the produced date is indicated for the operation panel
(guidance) ROMs.

FSM 4-27 A095/A096/A097

6 JAM/SC COUNTER
PAGE 1

Item Function Note

❶ Indicates the total number of Press to scroll up.

occurrences of each SC code.
Press to scroll down.
See Section 6 for details of each SC
code.
The counters for SCs that have not
occurred are not displayed.

A095/A096/A097 4-28 FSM

6 JAM/SC COUNTER
PAGE 2 PAGE 3

❶ ❹
❷
❸

❺
❻

Item Function Note

❶ Indicates the total number of jams in the

copier and all peripherals.

❷ Indicates the total number of jams in the

copier only.

❸ Indicates the total number of jams at Locations:

each location.

Service Tables
❹ Indicates the total number of jams for
each feed station.

❺ Indicates the total number of jams at

each location in the DF.

❻ Indicates the total number of jams in the

DF.

FSM 4-29 A095/A096/A097

7 COPY COUNTER
PAGE 1 PAGE 2

❶ ❺
❷
❸
❹ ❻

Item Function Note

❶ Indicates the total main motor rotation

time.

❷ Indicates the total number of originals

fed by the DF.

❸ Indicates the total number of copies.

❹ Indicates the total number of copies for

each paper size.

❺ Indicates the total number of copies for

each magnification.

❻ Indicates the total number of copies for

each edit image mode.

A095/A096/A097 4-30 FSM

7 COPY COUNTER
PAGE 3, 4

❶ ❶

PAGE 5 PAGE 6

❸ ❹

Service Tables
Item Function Note

❶ Indicates the total number of the copies

for each copy mode.

❷ Indicates the total number related to

consumables.

❸ Indicates the total number of staples for

each staple position.

❹ Indicates the total number of copies

broken down by paper feed station.

FSM 4-31 A095/A096/A097

8 COUNTER CLEAR
PAGE 1

❶
❷
❸
❹

PAGE 2

Item Function Note

❶ Clears all SC counters. Procedure to clear:

1. Touch Clear .
❷ Clears all paper jam counters. The display changes as shown at
right.
❸ Clears all original jam counters. 2. Touch Yes .
(Touch No to cancel.)
❹ Clears all copy counters. The display returns to the one
shown at left and the beeper
❺ Clears all counters (❶ ~ ❹). sounds four times.

A095/A096/A097 4-32 FSM

9 PM COUNTER CLEAR
PAGE 1

❶
❷

PAGE 2

Service Tables
Item Function Note

❶ 1. Indicates the total number of copies

since the last PM (PM counter).
Procedure to clear:
1. Touch Clear .
2. Clears the PM counter. The display changes as shown at
right.
❷ 1. Indicates the total number of copies
since the last PM for each unit
2. Touch Yes .
(unit counter). (Touch No to cancel.)
2. Clears each unit counter. The display returns to the one
shown at left.

FSM 4-33 A095/A096/A097

9 PM COUNTER CLEAR
PAGE 3, 4

Item Function Note

❶ 1. Indicates the total number of copies

since the last PM for each unit.
Procedure to clear:
1. Touch Clear .
(unit counter) The display changes as shown at
2. Clears each unit counter. right.
2. Touch Yes .
(Touch No to cancel.)
The display returns to the one
shown at left.

A095/A096/A097 4-34 FSM

10 MEMORY CLEAR Rev. 8/02/94
PAGE 1

❶
Clear

Item Function Note

❶ Returns all data to the default data. Procedure to clear:

1. Open the front door*.

2. Touch .
The display changes as shown at
right.
3. Touch Clear
Yes .

Service Tables
(Touch No to cancel.)
The display returns to the one
shown at left and the beeper
sounds twice.
4. Turn the main switch off and on.

* This step exists to eliminate clearing the data in RAM by mistake.

Counter clear (SC counter, PM counter, copy counter etc.) does not require
the front door to be opened.

NOTE: After clearing all memory, perform at least the following.

1. Perform the process data initial setting.
2. Install new developer and then perform the Toner Density sensor
(Developer) initial setting.
3. Input the Lens Error Correction data (SP Adjustment page 5: refer to
page 4-11 of the service manual).
For the other items, basically the default data is acceptable. Check the copy
performance and copy image and adjust copy image or timing if necessary.

FSM 4-35 A095/A096/A097

2.3 SENSOR/SWITCH/SIGNAL DATA CHECK (INPUT MODE)
– How to check the sensor/switch/signal –
1. Enter SP mode as follows:
1) Press the mode clear key.
2) Enter "107"
3) Press the clear/stop key for more than 3 seconds.

1 0 7 C

2. Touch 2 [A] on the display to

access SP test mode.

[A]

[B]
3. Touch Next [B] on the display
twice.

4. 1) Touch Input No. 00 [C].

[D]
2) Enter the input
sensor/switch/signal
number by using the number
keys (Refer to the table in the
following pages).

3) Press the Enter key [D]. [C]

A095/A096/A097 4-36 FSM

Rev. 10/94
Input Sensor/Switch/|Signal Status
No
0 1
1 Registration Sensor Paper not detected Paper detected
2 Fusing Exit Sensor Paper not detected Paper detected
3 Exit Sensor Paper not detected Paper detected
4 Vertical Transport Sensor Paper not detected Paper detected
5 1st Tray Set Switch (A095 only) Not set Set
6 By-Pass Paper End Sensor Paper detected Paper not detected
7 2nd Paper End Paper detected Paper not detected
8 3rd Paper End Paper detected Paper not detected
9 Built-in LCT Tray Down Key Pressed Not pressed
10 2nd Paper Near End Sensor Not near end Near end
11 3rd Paper Near End Sensor Not near end Near end
12 Built-in LCT Paper Set Paper detected Paper not detected
13 2nd Paper Size Switch (All SW) Set Not Set
14 2nd Tray Set Detection Not set Set
15 3rd Tray Set Switch (A095 only) Not set Set

Service Tables
16 Built-in LCT Set Detection Not set Set
17 1st Paper Feed Sensor Paper not detected Paper detected
18 2nd Paper Feed Sensor Paper not detected Paper detected
19 3rd Paper Feed Sensor Paper not detected Paper detected
20 Not Used — —
21 2nd Lift Sensor Not lifted Lifted
22 3rd Lift Sensor Not lifted Lifted
23 Built-in LCT Tray Down Sensor Tray at down Tray not down
24 Fusing Set Detection. Not set Set
25 Drum Unit Set Detection Not set Set
26 Right Tandem Paper End Sensor Paper detected Paper not detected
27 Left Tandem Paper End Sensor Paper detected Paper not detected
28 Right Tandem Tray Set Detection Not set Set
29 Left Tandem Tray Set Detection Not set Set
30 Rear Fence Return Sensor Not at return position At return position
31 Rear Fence HP. Sensor Not at HP At HP
32 Base Plate Down Sensor (Tandem) Not down Down
33 1st Paper Near End Sensor Not at near end Near end
34 1st Lift Sensor Not lifted Lifted
35 Side Fence HP. Sensor At HP Not at HP
36 3.5 K LCT Paper End Sensor Paper detected Paper not detected
37 3.5 K LCT Set Detection Not set Set

FSM 4-37 A095/A096/A097

Rev. 10/94
Input Sensor/Switch/|Signal Status
No
0 1
38 3.5 K LCT Lift Sensor Not lifted Lifted
39 3.5 K LCT Tray Down Key Not pressed Pressed
40 3.5 K LCT Feed Sensor Paper not detected Paper detected
41 3.5 K LCT Tray Down Sensor Tray not down Tray down
42 3.5 K LCT Door Switches Closed Open
43 3.5 K LCT Paper Position Sensor Paper not detected Paper detected
44 Duplex Jogger HP Sensor Not at HP At HP
45 Duplex Transport Sensor Paper not detected Paper detected
46 Duplex Entrance Sensor Paper not detected Paper detected
47 Duplex Exit Sensor Paper not detected Paper detected
48 Duplex Unit Set Detection Not set Set
49 Duplex Paper End Sensor Paper detected Paper not detected
50 Toner End Sensor Toner present No toner
51 Toner Overflow Switch No overflow Overflow
52 By-Pass Table Switch Closed Open
53 Front Door Safety Switch Closed Open
54 Toner Collection Bottle Set Switch Not set Set
55 By-Pass Feed Motor Lock Detection Not detected Detected
56 Development Motor Lock Detection Not detected Detected
57 Main Motor Lock Detection Not detected Detected
58 Not used — —
59 Paper Feed motor Lock Detection Not detected Detected
60 Fusing/Duplex Drive Motor Lock Not detected Detected
Detection
61 By-pass Paper Feed Motor Lock Not detected Detected
Detection
62 Duplex Paper Guide Sensor Paper not detected Paper detected
63 Not used — —
64 Not used — —
65 3.5 K LCT Paper Near End Sensor Paper detected Paper not detected
(Near end)
66 Guide Plate Position Sensor Closed Open
67 3.5 K LCT Motor Lock Not detected Detected
Input No 68 ~ 90 are not used.
91 Auto Response Sensor Not detected Detected
92 Key Counter Connector Open Short
Input No 93 ~ 100 are not used.

A095/A096/A097 4-38 FSM

Input Sensor/Switch/|Signal Status
No
0 1
101 Entrance Sensor (A377 S/S) Paper detected Paper not detected
Entrance Sensor (Finisher) Paper detected Paper not detected
102 Proof Exit Sensor (A377 S/S) Paper detected Paper not detected
Exit Sensor (Finisher) Paper detected Paper not detected
103 Jam Sensor (Photo transistor) Paper detected Paper not detected
(A377 S/S)
Shift Tray Half Turn Sensor At HP Not at HP
(Finisher)
104 Bin Sensor (Photo transistor) (A377 Paper detected Paper not detected
S/S)
Stack Height Sensor 2 (Finisher) At HP Not at HP
105 Bin HP. Sensor (A377 S/S) Not at HP At HP
Stack Height Sensor 1 (Finisher) Not at HP At HP
106 Wheel Sensor (A377 S/S) Not interrupted Interrupted
Shift Tray Lower Limit Sensor At lowest position Not at lowest position
(Finisher)
107 Bin Rear Plate Release Sensor Not at release At release position

Service Tables
(A377 S/S) position
Jogger Unit Entrance Sensor Paper detected Paper not detected
(Finisher)
108 Bin Rear Plate HP. Sensor (A377 Not at HP At HP
S/S)
Jogger Unit Paper Sensor (Finisher) Paper not detected Paper detected
109 Jogger HP. Sensor (A377 S/S) Not at HP At HP
Jogger HP. Sensor (Finisher) Not at HP At HP
110 Grip HP. Sensor (A377 S/S) Not at HP At HP
Staple Unit HP. Sensor (Finisher) Not at HP At HP
111 Staple Unit HP. Sensor (A377 S/S) Not at HP At HP
Stack Feed-out Belt HP. Sensor At HP Not at HP
(Finisher)
112 Staple HP. Sensor At HP Not at HP
Staple Hammer HP Sensor At HP Not at HP
(Finisher)
113 Staple End Sensor (A377 S/S) Present Empty
Staple End Sensor (Finisher) At HP Not at HP
114 Paper Sensor (A377 S/S) Paper detected Paper not detected
Not Used — —
115 Door Safety Switch (A377 S/S) Closed Open
Front Door Safety Switch Closed Open
116 Sorter Main Motor Encoder — —
(A377 S/S)

Input No 117 ~ 130 are not used.

FSM 4-39 A095/A096/A097

Rev. 4/15/94
Input Sensor/Switch/|Signal Status
No
0 1
131 Scanner HP. Sensor Not at HP At HP
132 Lens vertical HP. Sensor Not at HP At HP
133 Lens Horizontal HP. Sensor At HP Not at HP
134 3rd Scanner HP. Sensor Not at HP At HP
135 Platen Cover Position Sensor 1 Not interrupted Interrupted
136 Platen Cover Position Sensor 2 Not interrupted Interrupted
137 Optics Thermistor Low Temp. High Temp.
Input No 138 ~ 150 are not used.
151 Not Used (DJF) – –
One Turn Sensor (RDH) At HP Not at HP
152 Original Set SN(DJF) Original not detected Original detected
Pulse Generator Sensor (RDH) Interrupted Not interrupted
153 Original Feed SN (DJF) Original not detected Original detected
Original Set Sensor (RDH) Original not detected Original detected
154 Not Used (DJF) – –
Recycle Sensor (RDH) Original not detected Original detected
155 Lift Switch (DJF) Down Sifted
Original Width Sensor (RDH) Original not detected Original detected
156 Feed-out Motor Encoder Pulse – –
(DJF)
Registration Sensor (RDH) Original not detected Original detected
157 Belt Drive Motor Encoder Pulse – –
(DJF)
Inverter Sensor (RDH) Original not detected Original detected
158 Feed-in Motor Encoder Pulse (DJF) – –
Feed-out Sensor (RDH) Original not detected Original detected
159 Registration SN 2 (DJF) Original not detected Original detected
Not used – –
160 Original Width SN 1 (DJF) Original not detected Original detected
Transport Belt Motor Encoder Pulse – –
(RDH)
161 Original Width SN 2 (DJF) Original not detected Original detected
Feed-in Motor Encoder Pulse (RDH) – –
162 Original Width SN 3 (DJF) Original not detected Original detected
Inverter Motor Encoder Pulse (RDH) – –
163 Registration SN 1 (DJF) Original not detected Original detected
Feed-out Motor Encoder Pulse – –
(RDH)

A095/A096/A097 4-40 FSM

Input Sensor/Switch/|Signal Status
No
0 1
164 Feed-out SN (DJF) Original not detected Original detected
Lift Switch (RDH) Down Lifted
165 Not used (DJF) – –
RDH Position Sensor (RDH) Lifted Down
166 DF Position SN (DJF) Open Closed
Not used (RDH) – –
167 Feed Cover Switch (DJF) Closed Open
Not used (RDH) – –
168 Not Used (DJF) – –
Not used (RDH) – –
169 Original Length SN (DJF) Interrupted Not interrupted
Not used (RDH) – –

Service Tables

FSM 4-41 A095/A096/A097

2.4 ELECTRICAL COMPONENT CHECK (OUTPUT MODE)
CAUTION: The motors keep turning in this mode regardless of the
upper or lower limit sensor signal. Do not keep the
electrical component on for a long time to prevent
mechanical or electrical damage.

– How to check the motors/clutch/solenoids –

1. Enter SP mode as follows:
1) Press the mode clear key.
2) Enter "107".
3) Press the clear/stop key for more than 3 seconds.

1 0 7 C

2. Touch 2 [ A] on the display

to access SP Test mode.

[A]

3. Touch Next [A] on the display

twice.
[A]

A095/A096/A097 4-42 FSM

4. 1) Touch Output No. 000
[B].
2) Enter the electrical component [C]
number by using the number
keys on the operation panel.
(Refer to the table in the
following pages.)
3) Press the Enter key [C].
4) Press ON [D] to activate
and press OFF [E] to
de-activate the electrical [D] [E]
component. [B]
NOTE: When confirming the activating sound, keep the front door open.
If the front door is closed, when OFF is touched, a mechanical
noise caused by home positioning disturbs actual de-activating
sound.

Service Tables

FSM 4-43 A095/A096/A097

Rev. 7/94
Output Check Mode Table – 1
Output No. Electrical Component
1 Not used
2 Junction Solenoid
3 LCT Feed Clutch
4 By-pass Feed Clutch
5 Duplex Transport Clutch
6 Toner Supply Clutch
7 By-pass Pick-up Solenoid
8 Guide Plate Solenoid
9 LCT Pick-up Solenoid
10 Toner Bottle Motor
11 Duplex Feed Clutch
12 Pressure Arm Solenoid
13 Duplex Positioning Solenoid
14 LCT Down Key LED
15 Not used
16 Main Motor Forward
17 Main Motor Reverse
18 Fusing/Duplex Drive Motor
19 Development Motor
20 By-pass Feed Motor - Low Speed
21 By-pass Feed Motor - High Speed (First Copy from 1st feed tray)
22 LCT Motor - Up
23 LCT Motor - Down
24 Paper Feed Motor - Low Speed
25 Paper Feed Motor - High Speed (First Copy from 1st feed tray)
26 Anti-condensation Heater Relay
27 1st Pick-up Solenoid
28 2nd Pick-up Solenoid
29 3rd Pick-up Solenoid
30 Not used
31 1st Separation Roller Solenoid
32 2nd Separation Roller Solenoid
33 3rd Separation Roller Solenoid
34 Not used
35 Toner Collection Motor - High
36 Toner Collection Motor - Low
37 Tandem Lock Solenoid
38 1st Lift Motor (Up)
39 1st Lift Motor (Down)
40 2nd Lift Motor (Up)

A095/A096/A097 4-44 FSM

Rev. 7/94
Output No. Electrical Component
41 2nd Lift Motor (Down)
42 3rd Lift Motor (Up)
43 3rd Lift Motor (Down)
44 Not used
45 Not used
46 Rear Fence Drive Motor (Counterclockwise)
47 Rear Fence Drive Motor (Clockwise)
48 1st Paper Feed Clutch
49 2nd Paper Feed Clutch
50 3rd Paper Feed Clutch
51 Not used
52 Registration Clutch
53 Main Power Relay
54 Erase Lamp
55 Charge Wire Cleaner Motor
56 Transfer Belt Positioning Solenoid
57 Potential Calibration Mode (–100 V)

Service Tables
58 Potential Calibration Mode (–800 V)
59 QL/PTL
60 Charge Corona/Grid (Copying)
61 Charge Corona/Grid (ID Sensor Pattern)
62 Development Bias (Copying)
63 Development Bias (Non-image Area)
64 Development Bias (ID Sensor Pattern)
65 Transfer Current
66 Exhaust Fan - Low
67 Exhaust Fan - High
68 Not Used
69 Not Used
70 Optic Cooling Fan-2 (A097 copier only)
71 AC Drive Cooling Fan (A097 copier only)
72 Duplex Cooling Fan (A097 copier only)
Output No 73 ~ 100 are not used
101 Transport Drive Motor(Finisher); Main Motor: Proof Mode (A377 S/S)
102 Main Motor: Sort mode (A377 S/S)
Not Used (Finisher)
103 Exit Drive Motor (Finisher)
104 Turn Gate Solenoid (A377 S/S)
Junction Gate Solenoid (Finisher)
105 Bin Drive Motor (A377 S/S)
Positioning Roller Solenoid (Finisher)

FSM 4-45 A095/A096/A097

Rev. 7/94
Output No. Electrical Component
106 Jogger Motor (A377 S/S)
Jogger Motor (Finisher)
107 Bin Rear Plate Drive Motor (A377 S/S)
Shift Motor (Finisher)
108 Grip Motor (A377 S/S)
Stack Feed-out Motor (Finisher)
109 Grip Positioning Solenoid (A377 S/S)
Shift Tray Lift Motor (Finisher)
110 Grip Solenoid
Not used (Finisher)
111 Staple Unit Drive Motor (A377 S/S)
Staple Drive Motor (Finisher)
112 Staple Motor (A377 S/S)
Staple Motor (Finisher)
113 Not used (A377 S/S)
Not used (Finisher)
Output No 114 ~130 are not used
131 Optics Cooling Fan
Output No132 ~ 151 are not used
152 Not used (DJF) / Original Gate Solenoid (RDH)
153 Not used (DJF) / Inverter Solenoid (RDH)
154 LED "READY" (DJF) / Push Plate Solenoid (RDH)
155 LED "AUTO" (DJF) / Feed-in Clutch (RDH)
156 Not used (DJF) /Feed-in Motor (Clockwise) (RDH)
157 Feed-in motor (DJF) / Feed-in Motor (Counterclockwise) (RDH)
158 Feed-out Motor (DJF) / Feed-in Motor (Clockwise) (RDH)
159 Not used (DJF) / Feed-in Motor (Counterclockwise) (RDH)
160 Belt Drive Motor (DJF) / Transport Belt Motor (Forward) (RDH)
161 Not used (DJF) / Transport Belt Motor (reverse) (RDH)
162 Separation Solenoid - SADF (DJF) / Inverter Motor (RDH)
163 Not used (DJF) / Feed-out Motor (Low) (RDH)
164 Not used (DJF) / Feed-out Motor (High) (RDH)
165 Stopper Solenoid (DJF) / Friction Belt Motor (RDH)
166 Inverter Solenoid (DJF) / Not Used (RDH)
167 Feed-In Clutch (DJF) / LED "READY" ON (RDH)
168 Not Used (DJF) / LED "READY" OFF (RDH)

A095/A096/A097 4-46 FSM

2.5 USER TOOLS
This mode is for the key operators in charge of this copier. The operator can
change or set the copier’s default settings using the following user tools.

2.5.1 User Tools Menu

Service Tables

FSM 4-47 A095/A096/A097

2.5.2 How To Access The User Tools

1. Press the Clear Modes key.

2. Press the Clear/Stop key more than 3 seconds until the User Tool Menu
appears on the touch panel display.

3. Select the menu number to use by touching the touch panel display.

This copier has 12 user tools. You can see 5 user tools on the
touch panel display at the same time. Use these keys to see
the rest of the user tool menu.

Use to exit the user tool.

Use to return to the user tool menu display.

A095/A096/A097 4-48 FSM

1 Auto reset/Auto off
Auto reset The copier returns to its initial condition automatically after
your job is finished. The automatic reset time can be set
from 1 second to 999 seconds, or the function can be
turned off.
Default: 60 sec.
Screen Saver When the machine does not detect anyone operating it for
the selected time, the touch panel display turns off
automatically. This time can be set from 1 second to 999
seconds, or the function can be turned off.
Default: 60 sec.
Auto off When the copier is used after the weekly timer has turned
it off, the copier will turn itself back off after the selected
time. The auto off time can be set from 1 minute to 999
minutes, or the function can be turned off.
Default: OFF
SADF Auto reset In the SADF mode (Semi-Automatic Document Feed, see
(for machines with dual job page 23), if the next original is not set within the selected
feeder only) time, the machine will cancel the SADF mode
(system A or B) automatically. The SADF Auto reset time can be set from
1 second to 60 seconds, or the function can be turned off.
Default: 5 sec.

2 Select special tray

Tray for Cover Sheet Select the tray for the Cover function. Paper for cover
sheets will be fed from the selected tray.
Default: No select

Service Tables
Tray Display for You can see which tray is set for cover sheets. If you
Cover Sheet want to see the tray display only in the Cover mode, select
"Mode selected". If you want to always see the tray
display, select "Full time".
Default: Full time
Tray for Slip Sheet Select the tray for the Slip Sheet functions (Paper
Designate and OHP Slip Sheet). Paper for slip sheets will
be fed from the selected tray.
Default: No select
Tray Display for You can see which tray is set for the slip sheets. If you
Slip Sheet want to see the tray display only in the Slip Sheet mode,
select "Mode selected". If you want to always see the tray
display, select "Full time".
Default: Full time
• The trays set for cover sheets or slip sheets cannot be used for the Auto
Paper Select, Auto Tray Switching, and Duplex copying modes.

FSM 4-49 A095/A096/A097

3 Set date/time
Use to set the copier’s internal clock before setting the weekly timer. Set
the clock following the touch panel display instructions.
• If necessary, remember to adjust the clock for daylight saving time
(summer time), or return it to standard time.

4 Weekly Timer
Use to set the weekly timer. If you set the timer, the copier turns on and off
automatically at the selected time each day.
• Default: No weekly timer setting
• If you want to turn on the machine for an entire day, input "000" for the
ON time and do not input the OFF time.
• If you want to turn off the machine for an entire day (ex.: Saturday,
Sunday), do not input the ON time and input "000" for the OFF time.

A095/A096/A097 4-50 FSM

5 Set operation modes
Maximum copy input number The maximum copy quantity can be set from 1 to 999.
Default: 999
Panel beeper The beeper (key tone) can be set to on or off.
❐ default: ON
Job End Call The beeper (job end call) sounds when your copying job
is finished, supplies (toner, paper) run out, or if a problem
occurs in the machine. The Job End Call can be set to on
or off
Default: ON
Next Prev.
Image Density Level Auto and Manual Image Density levels can be adjusted to
be lighter or darker.

Default: (center)

Default Setting You can select Program No. 5 (see page 42) as a default
mode. Use it to store job settings you frequently use.
Default: Normal
Touch Panel in You can select the animation display during the warm-up
Waiting Mode period and copying run. During the warm-up period, the
remaining warm-up time is displayed. During copying,
you can see how long it takes to finish copying by
entering the number of originals with the Number keys
and Enter key. To exit the animation display, touch the

Service Tables
Exit key of the touch panel display.
Default: Reset (no animation display)

FSM 4-51 A095/A096/A097

6 Change fixed R/E
This copier has 10 fixed ratios (4 enlargements and 6 reductions). You can
change these fixed reproduction ratios to different ratios.

7 Set standard tray display

Paper Tray Priority When Auto Paper Select is canceled, the 1st tray is
selected as a default setting. You can cancel this setting
and select the other tray as a default setting.
Default: OFF
Auto Paper Select Priority As a default setting, the Auto Paper Select is selected.
You can cancel this setting.
Default: Yes
Paper Tray Display In the default setting, the tray display is shown only when
in APS mode the Auto Paper Select mode is canceled. You can cancel
this setting and have the tray display shown always.
Default: No
Auto Tray Switching If you load paper of the same size and in the same
direction in two or more paper trays, the machine
automatically shifts to the other tray when the tray in use
runs out of paper.
Default: Yes
Bypass feed tray, and trays for cover sheet and slip sheet
cannot be used for Auto Tray Switching.

A095/A096/A097 4-52 FSM

12 Select ARDF/RDH modes
This user tool can be used only when your machine is equipped with the
dual job feeder (system A and B) or the recirculating document handler
(system C).
Original Count Display In the default setting, you can see the entered copy
quantity on the upper part of the copy counter and the
number of copies made on the lower part. You can
cancel this setting and see the number of originals to be
fed on the lower part of the copy counter. On the upper
part, you can see the number of copies made. To cancel
the default setting, select "Yes".
Default: No
Auto Paper Select In the default setting, the Auto Paper Select is not
selected when you set originals in the dual job feeder or
recirculating document handler. You can cancel this
setting.
Default: No
Thin Paper mode Use when changing the type of originals to be fed. Select
(for machines with dual job this function when you use thin originals (lighter than 53
feeder only) g/m2, 14 lb).
(system A or B) Default: No
☞ Regarding User Tools No. 8, 9, 10, and 11, see the next page.

Service Tables

FSM 4-53 A095/A096/A097

User Tools for User Code Mode
If the copier is set to use the User Code function,
operators must input their user codes before the machine
can operate. The copier keeps count of the number of
copies made under each user code.

User tools 8, 9, 10 and 11 are for the User Code mode.

When you want to use these user tools, you should enter
the key operator access code first.

8 Set User Code(s)

Register Use to register your user code (maximum: 6 digits)
❐ Up to 500 user codes can be registered.
❐ Registered user codes will be sorted in numerical order.
Change Use to change your present code to a new one.
❐ The number of copies made under the old code is
added
to that made under the new user code.
Delete Use to delete your user code.
❐ The number of copies made under the code is deleted.

9 Check/Reset copy count

You can check the number of copies made using each user code. Also,
you can clear each code’s counter.

10 Reset data for User Codes

Use to reset counter data for all user codes.

11 Reset User Codes/Counters

Use to reset all user codes and counters.

A095/A096/A097 4-54 FSM

3. TEST POINTS / CHECK POINTS
3.1 MAIN CONTROL BOARD
TP Number Label Monitoring Signal
TP101 (PSN) ID Sensor Output
TP102 (TSN) TD Sensor Output
TP103 (VLT) Drum Potential Sensor Output
TP104 (D.TH) Drum Thermistor Output
TP105 (SIZE) By-pass Size Signal
TP106 (LAMP) Exposure Lamp Voltage Monitor
Signal
TP107 (FUSER) Fusing Thermistor Output
TP108 (+5V) VCC
TP109 (GND) GND
TP110 (+24V) VAA
CP101 — CPU2 → CPU1
CP102 — CPU1 → CPU2
CP103 — RXD SS
CP104 — TXD SS
CP105 — RXD

Service Tables
CP106 — TXD
CP107 — RXD
CP108 — TXD
CP109 — RXD
CP110 — TXD
CP111 — RXD
CP112 — TXD
CP113 — RXD ADF
CP114 — TXD ADF
CP115 — Not Used
CP116 — Not Used
CP117 — PRT CTS
CP118 — PRT SOUT
NOTE: TP101 ~ 110 have test pins.

FSM 4-55 A095/A096/A097

3.2 OPTICS CONTROL BOARD
TP Number Label Monitoring Signal
TP501 (ADS) ADS Sensor Output
TP502 (UNIT-TEMP) Optics Thermistor Output
TP503 (MOTOR-TEMP) Scanner Motor Thermistor Output
TP504 (GND) CGND
TP505 (+5V) VCC
TP506 (SC-START) Scanner Start Signal
TP507 (ENCODER-OUT) Scanner Encoder Signal

TP508 (LP-PWM) Exp. Lamp PWM

TP509 (HT-PWM) Fus. Lam PWM
TP510 (SC-PWM) Scanner PWM
TP511 (SC-DIR) Scanner DIR
TP512 (FREE-RUN) Scanner Free Run
TP513 (+24V) VAA
TP514 (UNIT-ADJ- Adjustment Mode
MODE)
TP515 (ZERO-CROSS) Zero Cross
TP516 (+38V) VMM
TP517 (RXD) RXD
TP518 (THRMST) Fusing Thermistor Output
TP519 (LAMP) Exposure Lamp Voltage
TP520 (LE) Lead Edge
TP521 (TXD) TXD
TP522 (SUB-IN) SUB IN
NOTE: TP504, 512, 514 have test pins.

3.3 OPERATION PANEL BOARD

TP Number Label Monitoring Signal
TP101 (CPUCK) CPU Check
TP102 (CLK) Clock
TP103 (FLM) Fluorescent Lamp Monitor
TP104 (GND) GND

A095/A096/A097 4-56 FSM

Rev. 10/94
4. PREVENTIVE MAINTENANCE SCHEDULE
4.1 PM TABLE
NOTE: The numbers mentioned for PM intervals indicate the number of
copies.
Symbol key: C: Clean R: Replace L: Lubricate I: Inspect
EM 120 K 240 K 360 K NOTE
OPTICS
Mirrors, Lens, Reflectors C C C Cotton pad with water, or blower
brush.
Exposure Glass C C C C Alcohol or glass cleaner.
Platen Cover Sheet C R R R Alcohol or water (replace if
necessary).
Scanner Guide Rail C C C Dry cloth.
Scanner/Lens Guide Rods L L L Refer to NOTE 1
ADS, Original Size sensor C C C C Blower brush.
Toner Shield Filter C C C C Dry cloth, Discharge any static
before installation.

Service Tables
PAPER FEED (for each paper feed station)
Paper Feed Rollers C R R R Water. Replace pick-up, feed,
(Paper Trays) and separation rollers as a set.

Paper Feed Rollers C R R R Water, replace pick-up, feed, and

(By-pass/LCT) separation rollers as a set.

Paper Feed Guide Plate C C C Alcohol.

Registration Sensor C C C Blower brush.
Vertical Transport Rollers C C C Water
Paper Dust Cleaner C C C Dry cloth or blower brush
Registration Rollers C C C Water or alcohol.
Vertical Transport Guide L Refer to NOTE 2
Pin

AROUND THE DRUM

Corona Wires C R R R Dry cloth or water.
Wire Cleaner R
Cleaner Drive Gear L Refer to NOTE 4
Charge Grid R R R Blower Brush.
VD, VL, ADS Pattern C C C C Dry cloth.
Drum Grounding Terminal I I R
End Blocks and Casing C C C C Water.

FSM 4-57 A095/A096/A097

Rev. 8/16/95
EM 120 K 240 K 360 K NOTE
Pre-Transfer Lamp Filter C C C C Dry cloth and blower brush.
Discharge any static before
installation.

Quenching Lamp C C C C Dry cloth and blower brush.

ID Sensor C C C C Blower brush.
Erase Lamp Unit C C C C Dry cloth.
Pick-off Pawls C C R C
Drum Potential Sensor C C C C Dry cloth or blower brush.
Cleaning Blade R R R
Cleaning Seal C C C Replace if necessary.
Cleaning Brush R
Toner Collection Bottle C C C C Empty used toner.
Cleaning Drive Section L Refer to NOTE 4

DEVELOPMENT UNIT
Developer R R R
Upper Seal C C C
Side Seals C C C
Air Filter R R R Vacuum cleaner
Toner Bottle Holder C C/L C/L C/L Dry cloth. Refer to NOTE 5
Toner Receiver C C C C Dry cloth.
Bias Terminal L Refer to NOTE 8

TRANSFER BELT UNIT

Transfer Belt C C R C Dry cloth, clean both sides.
Cleaning Blade R R R
Belt Drive/Guide/ C C C Dry cloth
Bias Rollers
Transfer Belt Terminal C C C Replace as necessary
(A096 3864)
Rear Spring Plate C C C Suitable Solvent
(A096 3860)

FUSING/PAPER EXIT UNIT

Hot Roller C R C Replace if necessary.
Pressure Roller and C R C Replace if necessary.
Pressure Roller Bearings
Stripper Pawls C C R C Replace.
Fusing Entrance and Exit C C C Suitable solvent.
Guides
Fusing Thermistor C/L C/L C/L Suitable solvent. Refer to NOTE 6

A095/A096/A097 4-58 FSM

Rev. 8/16/95
EM 120 K 240 K 360 K NOTE
Transport/Exit Rollers C Water.
Hot Roller Isolating L Refer to NOTE 6
Bushing
Oil Supply Roller R R R
Oil Supply Cleaning Roller R R R
Pressure Roller Cleaning R R R
Roller
Thermistor Film C C C C Replace/Reverse if necessary
(A096 4209) Apply Silicon Oil

DUPLEX (for duplex copies)

Feed Roller R R R
Separation Belts R R R
Pick-up/Transport Rollers C C C
Positioning Pins/Holes L L L Refer to NOTE 7

OTHERS
Ozone Filter R

Service Tables
Drive Belts I I I Replace if necessary.
Exit Sensor C C C Blower brush.
Bushings L Spindle oil.
Development Drive Gear C

SORTER STAPLER (A377)

Rollers C C C C Water.
Bins C C C Water.
Bushings L L L Use Launa oil or equivalent.
Gears L L L Use Grease–501.

SORTER STAPLER (A374)

Bins C C C Water.
Rollers C C C Water.
Bushings L L L Use Launa oil or equivalent.
Gears L L L Use Grease–501.
Exit Rollers & L L L Use Launa oil or equivalent.
Bushings

FSM 4-59 A095/A096/A097

Rev. 8/16/95
EM 120 K 240 K 360 K NOTE
RECIRCULATING DOCUMENT HANDLER
Transport Belts C C R C Belt cleaner. Replace if
necessary.
Feed Roller C R R R Alcohol. Replace if necessary.
Separation Belt C R R R Alcohol. Replace if necessary.

DUAL JOB FEEDER (A376) (for copies)

Transport Belt C R R R Belt cleaner. Replace if
necessary.
Pick-up Roller C C C C Alcohol. Replace if necessary.
Feed Roller C R R R Alcohol. Replace if necessary.
Separation Belts C R R R Alcohol. Replace if necessary.

FINISHER
Rollers C C C Water.
Bushings L L L Use Launa oil or equivalent.
Gears L L L Use Grease–501.

A095/A096/A097 4-60 FSM

The location of the parts which should be lubricated at PM, are shown in the
following figures:

NOTE 1: Scanner/Lens Guide Rods

(1) Lubricate the horizontal and vertical
lens guide rods [A] with Launa Oil
every 120 K copies.

[A]

[A]

Service Tables
(2) Lubricate the third scanner guide
rod [B] with Launa oil every 120 K
copies.

[B]

FSM 4-61 A095/A096/A097

NOTE 2: Vertical Transport Guide Lock Pin
(1) Lubricate the vertical transport
guide lock pin [A] with Mobil Temp.
78. every 240 K copies.

[A]

NOTE 3: Charge Wire Cleaner Drive Gears

1. Open the drive motor cover [B] (2
screws).
NOTE: When re-installing the cover,
do not tighten the screws
too much.
2. Lubricate the charge wire cleaner
drive gears [C] with Grease G501
every 240 K copies.

[B]

[C]

A095/A096/A097 4-62 FSM

Rev. 4/15/94
NOTE 4: Cleaning Drive Section
(1) Lubricate the cleaning blade shift
cam gear [A] with Grease G501
every 240 K copies.

[A]

(2) Lubricate the cleaning section drive

gear [B] with Grease G501 every
240 K copies.

Service Tables
[B]

NOTE 5: Toner Bottle Holder

(1) Lubricate the toner bottle drive
gears [C] with Grease G501 every [C]
120 K copies.

(2) Lubricate the toner bottle holder [D]

with Mobil Temp. 78 every 120 K
copies.

[C]

[D]

FSM 4-63 A095/A096/A097

Rev. 8/16/94
NOTE 6: Fusing Section
(1) Clean the surface of
the fusing thermistor
[A] where touching
the hot roller.

[A]

(2) Lubricate the inner

and outer surface
of the isolating
bushing [B] with
BARRIERTA
L55/2 grease
every 240 K
copies.
[B]
[B]

[C] [D]
NOTE 7: Duplex Unit
(1) Lubricate the two positioning pins
[C] and two positioning Holes [D]
with Mobil Temp. 78 every 120 K
copies.

[D]

[C]

A095/A096/A097 4-64 FSM

NOTE 8: Development Unit

(1) Lubricate the bias terminal (sleeve roller

shaft) [A] with Grease: KS660: SHIN-ETSU

[A]

CAUTION: Use only conductive grease, otherwise bias voltage will

not be properly applied to development rollers.

Service Tables

FSM 4-64 A A095/A096/A097

This page intentionally left blank.

A095/A096/A097 4-64 B FSM

Rev. 7/94
4.2 EXPLANATION OF REGULAR PM
Item Explanation
Optics Unit Mirrors, Lens, Stains on any part of the optics unit result in black
Reflector, Exposure lines or areas of decreased sharpness on the copy
Glass, Platen Cover, image. Periodic cleaning is required. The exposure
Toner Shield Filter glass and the platen cover sheet must also be
cleaned. If stains on the platen cover sheet cannot
be removed, it must be replaced.
Exposure Lamp Deterioration of the exposure lamp affects the copy
image. Check the lamp at regular intervals and
replace if discolored.
VD, VL, ADS If paper dust or toner accumulates on the VD, VL,
Patterns ADS Patterns, the image density cannot be
controlled correctly. This results in light or dark
copies. Clean these patterns at regular intervals.
Transfer Transfer Belt A dirty or old transfer belt causes poor image
Belt Unit transfer due to its weak chargeability. Clean (both
front and rear sides) or replace the transfer belt at
regular intervals.
Belt Drive/ Dirty rollers shift the transfer belt to the front or rear.
Guide/Bias

Service Tables
Rollers
Cleaning Blade A dirty or worn out cleaning blade will cause toner to
adhere on the rear side of the copy. The blade must
be replaced at regular intervals.
Paper Feed, Paper Feed Roller, This machine uses paper trays, a by-pass feed table,
Registration Pick-up Roller, and an LCT for paper feeding. If paper dust adheres
Separation Roller to the paper feed rollers or if these rollers are worn
out, paper may not feed correctly, or skewing may
result. Replacing is required at regular intervals.
Registration Roller A dirty registration roller can cause paper to register
incorrectly, skew, or jam. Cleaning is required at
regular intervals.
Paper Dust Cleaner Too much paper dust caught in the cleaner causes
paper dust overflow. This results in early
deterioration of the cleaning blade, fusing rollers, etc.
Clean at regular intervals.
Registration Sensor A dirty registration sensor causes paper jams. Clean
at regular intervals.

FSM 4-65 A095/A096/A097

Rev. 7/94
Item Explanation
Around the Charge Wires/ Dirty charge wires may cause uneven image density.
Drum Wire Cleaner/ They should be replaced at regular intervals.
Charge Grid
End Blocks Toner tends to accumulate on the corona end
blocks, this can result in a high voltage leak. Clean
end blocks at regular intervals.
Drum Grounding Too much drum grounding terminal deterioration
Terminal causes poor drum grounding. This results in dirty
backgrounds and drum potential sensor calibration
errors.
QL If toner accumulates on the QL, a dirty background
or a repeating negative image may result.
Clean the QL at regular intervals.
PTL If paper dust or toner accumulates on the PTL filter,
its efficiency may be reduced. This can cause toner
to be reattracted to the drum during transfer,
reducing image density. Clean the PTL filter at
regular intervals.
ID Sensor If too much paper dust or toner accumulates on the
ID sensor, the toner density cannot be controlled
correctly. This results in light copy or over toning.
Clean this sensor at regular intervals.
Erase Lamp If toner accumulates on the erase lamp, a dirty
background may occur in the erased area that
becomes progressively worse in long copy runs.
Also this affects sensor pattern detection, causing
incorrect toner density and exposure lamp control.
Clean this lamp at regular intervals.
Cleaning Blade A dirty or worn out cleaning blade will cause black
lines on copies or scratches on the drum. The blade
must be replaced at regular intervals.
Cleaning Brush A worn out cleaning brush will not clean the drum
surface effectively, resulting in a dirty background
and damage to the cleaning blade. Replace at
regular intervals.
Toner Collection If the toner collection bottle becomes full, a service
Bottle call condition occurs and copying is prohibited.
Empty the toner collection bottle at regular intervals.
Pick-Off Pawls After long usage, the point that touches the drum
becomes worn and the area contacting the drum is
increased. This may cause drum filming, resulting in
vertical gray lines on the copy image.

Development Developer The tribo-chargeability of overused developer

Unit decreases. This results in toner scattering.
Developer must be replaced at regular intervals.

Bias Terminal Less lubricant increases the friction between the bias
terminal and the bias receptacle. This may
deteriorate the terminal.

A095/A096/A097 4-66 FSM

Rev. 8/16/95
Item Explanation
Fusing Unit Thermistor If toner accumulates on the thermistor film, fusing
temperature control may not be accurate. Clean the
thermistor film at regular intervals.
Stripper Pawls Toner or dust adhering to the stripper pawls can
cause a paper jam. Clean or replace the pawls at
regular intervals.
Fusing Entrance and Toner piling up on the guide plate will cause dirty
Exit Guides background on the copy or paper jam. Clean the
guide plate at regular intervals.
Oil Supply Roller If the oil inside is used up, toner and paper powder
adhere on the surface of the hot roller resulting in
hot-offset problem.
Pressure Roller Too dirty a cleaning roller applies a heavy load to
Cleaning Roller fusing/duplex drive motor, resulting in SC520.
Oil Supply Roller Too dirty a cleaning roller cannot clean foreign
Cleaning Roller substance on the oil supply roller. This causes stains
on the copy image.
Duplex Unit Separation/Feed/ If paper dust adheres to the
Transport Rollers separation/feed/transport rollers and the separation
and Separation Belts belts, paper may not feed correctly, or skewing may
result. Replacement is required at regular intervals.

Service Tables
Others Ozone Filter When an ozone filter deteriorates, ozone produced in
the copier will not be absorbed. This may cause
headaches, irritation, or other discomforts. Replace
at regular intervals.
DJF Transport Belt A dirty transport belt can leave stains on copies.
Replace the belt at regular intervals.
Pick-up Roller, Feed When dirty, these rollers and this belt can leave
Roller, Separation stains on the copy paper. Also, original misfeeds or
Belt multi-feeds may occur. Replace these parts at
regular intervals.
RDH Transport Belt A dirty transport belt can leave stains on copies.
Clean or replace the belt at regular intervals.
Feed Roller When dirty, these rollers and these belts can leave
Separation Belts stains on the copier. Also, original misfeeds or
multi-feeds may occur.
Replace these parts at regular intervals.

FSM 4-67 A095/A096/A097

Rev. 7/94
4.3 REGULAR PM PROCEDURE
Every 120 K
Every 240 K or 360 K

1. Make a copy Make a copy of O-S-A3 test chart at manual

image density level 4.

2. Optics (every 120 K) 2-1. Clean the mirrors, lens and reflectors by
using a soft cloth, cotton pad with water, or
a blower brush.
2-2. Clean the exposure glass with alcohol or
water.
2-3. Clean the scanner guide rail with a dry cloth.
2-4. Clean the magnification guide rail with a dry
cloth.
2-5. Clean the ADS sensor and the original
width and length sensors with a blower
brush.
2-6. Inspect the exposure lamp, if necessary,
replace it.
2-7. Lubricate the lens and 3rd scanner drive
guide rods. [Launa oil]
3. Around the Drum
(every 120 K) 3-1. Remove and open the drum unit and clean
the ID and Drum Potential sensors with a
blower brush.
Lubricate the cleaning 3-2. Clean the pick-off pawls and the toner
drive gears (every 240 shield filter. Discharge any static electricity
K) [Grease-G501] on the filter.
3-3. Clean the QL and PTL filter, and erase
lamp with a dry cloth, discharge any static
Replace the wire before installation.
cleaner and lubricate 3-4. Clean the end blocks and casing with
the drive gears water or alcohol.
[Grease-G501]
3-5. Replace the grid plate and corona wire.
(every 240 K)
3-6. Clean the registration rollers and paper dust
cleaner.
Replace the cleaning
brush (every 240 K) 3-7. Empty the toner collection bottle.
3-8. Clean the inside of the cleaning section,
Replace the pick-off cleaning brush, and seals.
pawl (every 240 K) 3-9. Replace the cleaning blade.

A095/A096/A097 4-68 FSM

Rev. 8/16/95

4-1. Remove the developer.

4. Development unit 4-2. Clean the development unit and gears.
(every 120 K)
4-3. Pour a pack of new developer.
4-4. Replace the air filter.
Lubricate the bias 4-5. Clean the toner bottle holder and toner
terminal receiver.
(every 240 K) 4-6. Lubricate the bottle drive mechanism.
(Grease: KS660: [Grease G-501]
SHIN-ETSU)

5-1. Clean the paper guide plates and vertical

5. Paper feed transport/relay rollers.
(every 120 K for each
5-2. Replace the paper feed, pick-up, and
Feed Station) separation rollers.
Note:
The feed (pick-up, feed, separation) rollers
for the 1st ∼ 3rd feed trays are different from
the feed rollers for the by-pass feed table
and 3.5 K LCT.

Service Tables
There is no interchangeability.
5-3. Clean the registration sensor.
5-4. Lubricate the transport guide lock pin.
6-1. Clean the transfer belt.
6. Transfer belt unit
6-2. Replace the transfer unit cleaning blade.
(every 120 K)
6-3. Clean the belt drive/guide rollers and bias
roller.
6-4. Clean the transfer belt terminal and the rear
Replace the spring plate.
transfer belt
(every 240 K)

7-1. Replace the separation roller and

7. Duplex unit separation belts.
(every 120 K) 7-2. Clean the feed and transport rollers.
7-3. Lubricate the duplex positioning pins.

FSM 4-69 A095/A096/A097

Rev. 8/16/95

8-1. Clean the entrance and exit guide plates.

8-2. Clean the thermistor film and apply Silicone
oil.
8. Fusing unit 8-3. Clean the stripper pawls.
(every 120 K)
8-4. Replace the oil supply roller.
8-5. Replace the oil supply roller cleaning roller. (A097
Replace stripper only)
pawls, hot roller, 8-6. Replace the pressure roller cleaning roller.
pressure roller, and
pressure roller
bearings. Lubricate
the isolating busing.
(every 240 K) 9-1. Clean the exit rollers.
9-2. Inspect the antistatic brush.
9. Exit unit 9-3. Clean the exit sensor.
(every 80 K)

Replace the
ozone filter
10-1. Lubricate the gears.
(every 360 K)
10-2. Inspect the timing belts.

10. Rear side

(every 80 K)

Replace the drum

grounding plate
(every 360 K)
11-1. Clean the covers.

11. Exterior
(every 80 K) 12-1. Perform the developer initial setting.
( 1 SP Adjustment – PAGE 1).
12-2. Perform the process control data initial
12. Copy Quality setting. ( 1 SP Adjustment – PAGE 1).

CAUTION: Perform the developer initial setting only when new

developer is installed.
Never make any copies before the developer initial setting.

A095/A096/A097 4-70 FSM

REPLACEMENT
AND ADJUSTMENT
1. EXTERIOR AND INNER COVER REMOVAL
1.1 FRONT SIDE
[B]
[C]

[G]

[A]

[F]

Replacement &
Adjustment
[E]
1.1.1 Left Front Cover
1. Open the left front door [A].
[H]
2. Pull out the pin [B].
[D]
3. Unhook the upper pin [C].

1.1.2 Right Front Door

1. Open the left front door [D].
2. Open the right front door [E].
3. Lower the pin [F] to unhook the upper hinge bracket [G].
4. Unhook the lower pin [H].

FSM 5-1 A095/A096/A097

1.2 REAR SIDE
[B]

[A]

[C]

[D]
1.2.1 Upper Rear Cover
1. Turn off the main switch.
2. If the DJF or RDH is installed, disconnect the fiber optics connectors [A]
and [B].
NOTE: After the upper rear cover is re-installed, set the fiber optics
connectors [A] and [B] so that the fiber optic cable [A] is located
over the electrical cable [B]. Also, the fiber optic cable [A]
should not bend while opening and closing the DJF or RDH.
3. Remove the upper rear cover [C]. (4 screws)

1.2.2 Lower Rear Cover

1. Remove the lower rear cover [D]. (6 screws)
NOTE: When installing the lower rear cover, set the hooks in the holes
on the right and left side covers.

A095/A096/A097 5-2 FSM

[B]
[A]

[C]

Replacement &
1.2.3 Left Inner Cover

Adjustment
[D] [E]
1. Remove the left front door [A].
2. Remove the left inner cover (4 screws) [B].

1.2.4 Right Inner Cover

1. Open the right door [C].
2. Remove knob B1 [D] (1 screw).
3. Remove the right inner cover [E] (2 screws).

FSM 5-3 A095/A096/A097

1.2.5 Shutter Inner Cover

[D]

[E]
[C] [A]

[A] [B]

[A]

1. Open the right door. [D]

2. Remove the shutter cover [A] by releasing the hook [B].
3. Remove the shutter inner cover [C] (1 screw).
NOTE: 1. Be sure to move the lever [D] until it contact the part [E].
2. While installing the shutter cover [A], the lever [D] must be
pushed as shown.

A095/A096/A097 5-4 FSM

1.3 RIGHT SIDE
1.3.1 Feed Unit Cover

[A]

[D]
[B]

[B]
[B]

[C]
[C]

1. Open the by-pass table [A] approximately 45 degrees and push the

Replacement &
stoppers [B] of the feed unit cover [C] by using a small flat head screw

Adjustment
driver [D], then remove the feed unit cover.

FSM 5-5 A095/A096/A097

[D]
[C]

[B]
[E]
[A]

[F]
1.3.2 Upper Right Cover
1. Remove the right inner cover [A], shutter cover [B] and the shutter inner
cover [C]. (Refer to Shutter Inner Cover Removal.)
2. Remove the upper rear cover [D]. (Refer to Upper Rear Cover Removal.)
3. Open the manual feed table and remove the upper right cover [E] (6
screws).

1.3.3 Lower Right Cover

1. Remove the lower rear cover. (Refer to Lower Rear Cover Removal.)
2. Open the right door.
NOTE: When installing the lower right cover, set the hooks in the holes
on the right and left side covers.
3. Remove the lower right cover [F] (4 screws).

A095/A096/A097 5-6 FSM

1.4 LEFT SIDE

[B]

[A]

[C]

[D]

[E]

Replacement &
1.4.1 Upper Left Cover

Adjustment
1. Remove the left inner cover. (Refer to Left Inner Cover Removal.)
2. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.)
3. Remove the upper left cover [B] (4 screws).
NOTE: When installing the upper left cover, set the hooks in the holes
on the right and left side covers.

1.4.2 Lower Left Cover

1. Pull out the second and the third feed trays [C].
2. Remove the lower rear cover [D].
3. Remove the lower left cover [E] (4 screws).
NOTE: When installing the lower left cover, set the hooks in the holes
on the right and left side covers.

FSM 5-7 A095/A096/A097

1.5 OPERATION PANEL

[B]

[A]
[E]
[D]

[C]

1. Turn off the main switch.

2. Remove the left door. (Refer to Left Door Removal.)
3. Remove the left inner cover. (Refer to Left Inner Cover Removal.)
4. Open the right door.
5. Open the toner bottle.
6. Remove three screws [A].
7. Remove two screws [B] securing the protective earth wires.
8. Insert the screw driver through the hole [C] and push the operation panel
[D] up.
9. Disconnect the connector [E].
NOTE: Be sure not to damage the harness by pulling the connector too
strongly.

A095/A096/A097 5-8 FSM

1.6 UPPER SIDE
[A]

[D]

[C]

[A]

[B]

[A] [F]
[E]
[E]

1.6.1 Upper Cover

1. Turn off the main switch.

Replacement &
Adjustment
2. Remove six screws [A].
3. Remove two screws [B] securing the grounding wires.
4. Disconnect two connectors [C].
5. Remove the upper cover [D].

1.6.2 Rear Upper Cover

1. Turn off the main switch.
2. Remove the platen cover or document feeder (DJF or RDH) from the
copier.
3. Remove the upper cover.
4. Remove the 2 screws securing the rear upper cover [E].
5. Disengage the hooks [F] by sliding the rear upper cover to the front and
remove it.

FSM 5-9 A095/A096/A097

Rev. 4/15/94
2. OPTICS
2.1 EXPOSURE GLASS REMOVAL
[A]

[B]

[D]
[C]

1. Turn off the main switch.

2. Remove the left scale [A] (2 shoulder screws).
3. Remove the rear scale [B] (3 screws).
4. Grasp the left edge of the exposure glass [C] and lift slightly. Slide the
other edge out from under the right glass holder [D]. Remove the
exposure glass.
NOTE: When reinstalling the exposure glass, make sure that the mark
(white: A096 copier/red: A095 copier) on the edge of the glass is
located at the rear right corner. This side is smoother and it
generates less static electricity when the RDH is used.

A095/A096/A097 5-10 FSM

2.2 EXPOSURE LAMP REPLACEMENT
[E]
[C]

[D]

[B]

[A]
NOTE: Do not touch the reflector or the new exposure lamp with your
bare hands. Use a strip of paper as shown. (Oil marks from
fingers on the lamp or reflectors will be affected by heat from the
lamp.)
1. Remove the exposure glass. (Refer to Exposure Glass Removal.)

Replacement &
2. Move the first scanner [A] to the cutout position at the rear frame [B].

Adjustment
(See illustration.)
3. Remove the reflector cover [C] (2 screws).
4. While holding the lamp with the paper strip, release the lamp terminal [D]
as shown; then, take out the lamp.
5. Install a new lamp. Use a strip of paper as shown to hold the lamp.
Confirm that the lamp is properly set by both terminals and that the clip
[E] is set properly.

FSM 5-11 A095/A096/A097

[A]

NOTE: Make sure that the blister [A] on the lamp points towards the
reflector opening (left side of the copier) as shown.
6. Reassemble the copier.
7. Turn on the main switch and enter SP mode, then perform the process
control data initial setting ( 1 SP Adjustment – PAGE 1).

A095/A096/A097 5-12 FSM

2.3 OPTICS THERMOSWITCH REPLACEMENT

[B]

[D]

[A]
[C]
[E]

NOTE: The thermoswitch can be reset manually by pushing the red button
[A] when the exposure lamp area cools.

Replacement &
Adjustment
1. Remove the exposure glass. (Refer to Exposure Glass Removal.)
2. Move the first scanner to the cutout position at the rear frame.
3. Remove the reflector cover [B] (2 screws).
4. Remove the exposure lamp leads [C] from the terminals on both sides of
the thermoswitch [D].
5. Remove the thermoswitch bracket [E] (1 screw).
6. Remove the thermoswitch from the bracket (2 screws), and replace it.

FSM 5-13 A095/A096/A097

2.4 SCANNER HP SENSOR REPLACEMENT

[B]

[A]

[E]

[D]

[C]

1. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.)
2. Remove the exhaust fan [B] (3 screws).
3. Manually turn the scanner drive pulley [C] counterclockwise to move the
scanners about 10mm to the left (rear view).
4. Remove the scanner HP sensor bracket [D] (1 screw).
5. Disconnect the connector.
6. Replace the scanner HP sensor [E] (1 screw).

A095/A096/A097 5-14 FSM

2.5 ADS SENSOR REMOVAL

[A]

[B]

[C]

Replacement &
Adjustment
[D]
1. Remove the exhaust fan [A]. (Refer to Scanner HP Sensor
Replacement.)
2. Remove the DJF/RDH connector bracket [B] (2screws).
3. Remove the ADS Sensor [C] with the cover [D] (1screw).
4. Replace the ADS Sensor [C] (2 screws).
5. Assemble the copier.
6. Turn on the main switch and enter SP mode, then perform the Auto ADS
initial setting ( 1 SP Adjustment-PAGE 5).

FSM 5-15 A095/A096/A097

2.6 SCANNER DRIVE MOTOR

[D]

[E]

[F]
[H] [I]
[C]
[A]
[B]

0.5 mm

[G]
1. Remove the exhaust fan. (Refer to Scanner HP Sensor Replacement.)
2. Remove the tension spring [A].
3. Remove the tension tightener [B].
NOTE: Re-install the tightener as follows;
1) Hook part [C] of the bracket on the screw [D] installed on the
scanner drive motor bracket.
2) Hook the tension spring [A].
3) Install two screws.

4. Remove the two connectors [E] from the Optic Control Board.
5. Remove the scanner motor [F] (4 screws).
NOTE: While replacing the drive pulley, the gap [G] should be 0.5mm so
that the upper edge [H] of the pulley is lower than the upper
surface [I] of the bracket, as shown. After installing the scanner
motor, perform the scanner control adjustment. (Refer to
Scanner Control Adjustment.)

A095/A096/A097 5-16 FSM

2.7 SCANNER DRIVE WIRES REPLACEMENT
- Removal -

[A]

[B]

[C]

Replacement &
Adjustment
1. Turn off the main switch.
2. Remove the exposure glass.
3. Remove the upper cover and the rear upper cover.
4. Remove the optics thermistor [A] (1 screw, 1 harness clamp).
5. Remove the scanner HP sensor with bracket . (Refer to Scanner HP
Sensor Replacement.)
6. Remove the scanner drive motor. (Refer to Scanner Drive Motor
Replacement)
7. Unhook the harness from the two harness clamps [B].
8. Remove the upper optics frame [C] (9 screws).

FSM 5-17 A095/A096/A097

[A]
[C]

[B]

[E]

[D]

[F]

[G]
9. Remove the lens unit cover [A] (2 screws).
10. Unhook the tension spring [B].
11. Remove the lens shield plate [C].
NOTE: When installing the lens shield plate, set the rear part [D] of the
lens shield plate between the guides [E] as shown. Then set the
grooves on the guide pins [F] in the rail [G].
After reinstalling the tension spring, confirm that movement of
the lens shield plate is smooth.

A095/A096/A097 5-18 FSM

[A]

[F] [D]
[B]

Replacement &
Adjustment
[E] [C]

12. Remove the front bracket [A] (2 screws).

13. Remove the screw [B] securing the scanner flat cable.
14. Unhook the four harness clamps [C].
15. Disconnect the connector [D] outside the optic side frame.
16. Remove the connector [E] from the optic side frame.
17. Remove the scanner clamps [F] securing both sides of the first scanner
unit to the scanner wires (4 screws).

FSM 5-19 A095/A096/A097

[A]

[D]

[C]

[B]

[E]

[F]

[G]

18. Remove the harness cover [A] (2 screws).

19. Remove the light shield mylar bracket [B] (1 screw).
20. Disconnect the paper length size sensor connector [C] and move the
lens unit to the left, then remove the rear bracket [D] (2 screws).
21. Unhook the tension spring [E] and remove the scanner wire [F].
22. Remove the second scanner [G].
NOTE: When re-installing the mylar bracket [B], be sure not to create
any gap between the bracket and the lens cover.

A095/A096/A097 5-20 FSM

[C]
[B]

[A]

[F]

Replacement &
Adjustment
[E]
23. Remove the left inner cover [A] (4 screws). [D]

24. Remove the E-ring [B] of the scanner drive shaft and remove the front
ball bearing [C].
25. Remove the rear drive pulley [D] (1 Allen screw) and remove the rear ball
bearing [E].
26. Loosen the two Allen screws of the front drive pulley [F] and slide the
pulley about 10 cm to the rear then take out the drive shaft.

FSM 5-21 A095/A096/A097

- INSTALLATION -

[B]
[E]
[A]

[C]

[F]

[D]

1. Round the rear scanner drive wire on the rear pulley as follows:

1) Align the cut out [A] on the edge of the rear drive pulley and the blue
mark [B] on the wire as shown.
2) Round the wire counterclockwise 5 times as shown (in the illustration,
the D-cut [C] on the shaft is at the front side) then set the bead [D] on
the wire in the hole [E] on the pulley.
(In this condition, the bead just reaches the hole on the pulley.)
3) After setting the bead in the hole, round the wire two more times (in
total 7 times).
4) Fix the wire with tape [F] as shown.

A095/A096/A097 5-22 FSM

[B]

[D]

[A]

[E]

[C]

Replacement &
2. Round the front scanner drive wire on the front pulley as shown:

Adjustment
1) Align the cut out [A] on the edge of the front drive pulley and the red
mark [B] on the wire.
2) Round the wire clockwise 5 times as shown (in the illustration, the
Allen screw holes are at the rear side) then set the bead [C] on the
wire in the hole [D] on the pulley.
(In this condition, the bead just reaches to the hole on the pulley.)
3) After setting the small ball in the hole, round the wire twice more (in
total 7 times).
4) Fix the wire with tape [E] as shown.

FSM 5-23 A095/A096/A097

[D]
[A]
[B]
[C]
[C]
[F]

[E]

[I]

[G]
[H]

3. Set the front drive pulley [A] on the drive shaft. (Leave the Allen screws
loosened.)
4. Place the scanner drive shaft [B] in the holes on the optics front and rear
side frames.
5. Set ball bearings [C] on both sides of the scanner drive shaft.
6. Set the E-ring [D] on the front end of the scanner drive shaft.
7. Set, and fully push in, the scanner drive pulley [E] on the front end of the
scanner drive shaft, then tighten the Allen screw [F].
8. Install the scanner drive motor. (Refer to Scanner Drive Motor
Replacement.)
9. Place the second scanner [G] on the guide rail and fix it there by using
two jig pins [H].
NOTE: This jig pin is used as the left door hinge pin [I]. However, only
one pin is used on the copier, so it is necessary to prepare
another one.

A095/A096/A097 5-24 FSM

➍ ➋ ➌

➊
[B]

[A]

10. Route the shorter end [A] of the rear scanner drive wire in the following
order.

➊ Rear track counterclockwise

➋ Clockwise
➌ Lower track clockwise.

Replacement &
Adjustment
➍ Fix the end of the wire on the frame with tape [B].

FSM 5-25 A095/A096/A097

➌

[B]

➍
[A]

11. Route the longer end [A] of the rear scanner drive wire in the following
order.

➊ Through front track, upper side.

➋ Counterclockwise.
➌ Upper track counterclockwise.
➍ Hook the end [B] of the wire on the cutout on the right optics side
frame.

A095/A096/A097 5-26 FSM

➋ ➍ ➌

[B]

➊
[A]

12. Route the shorter end [A] of the front scanner drive wire in the following
order.

➊ Front track counterclockwise

Replacement &
➋ Clockwise

Adjustment
➌ Lower track clockwise.
➍ Fix the end of the wire on the frame with tape [B].

FSM 5-27 A095/A096/A097

[C]
➍

[B]

[D]

➊ ➋

[A]

13. Route the longer end [A] of the front scanner drive wire in the following
order.

➊ Through rear track, upper side.

➋ Counterclockwise.
➌ Upper track clockwise.
➍ Hook the end of the wire [A] on the cut out on the right optics side
frame.

14. Slightly push the front drive pulley [B] against the front optics side frame
and tighten the two Allen screws.
15. Remove the jig pins securing the second scanner.
16. Remove the tapes [C] fixing the ends of the scanner drive wires and
hook the ends of the scanner drive wires with the tension springs.
17. Remove the tapes [D] fixing the wire to the front and rear drive pulleys.

A095/A096/A097 5-28 FSM

[C]

[A]

[B]

[E]
[D]

[G]

[F]

Replacement &
Adjustment
18. Install the rear bracket [A] (2 screws, 1 connector), shielding mylar
bracket [B] (1 screw) and harness cover [C] (2 screws).
19. Adjust the second scanner alignment as follows:

- Second Scanner Alignment -

1) Move the second scanner [D] to the left end position. Fix the rear side
of the second scanner by inserting the jig pin [E] in the holes on the
rear side of the second scanner and the rear guide rail.
2) Turn the adjusting nut [F] to adjust the second scanner alignment so
that the jig pins [G] can be smoothly set in the holes on the front side
of the second scanner and the front guide rail.

FSM 5-29 A095/A096/A097

[E]
[B] [D]
[C]

[A]

[D]

[F]

20. Place the first scanner unit on the guide rail then adjust the first scanner
alignment as follows:

- First Scanner Alignment -

1) Move the first scanner [A] to the left end position. Fix the rear end of
the first scanner by inserting the jig pin [B] in the holes on the first
scanner and the guide rail.
2) Position the first scanner so that the jig pin [C] can be smoothly set in
the holes on the first scanner and the guide rail, then tighten the wire
clamp brackets [D] (4 screws).

21. Install the scanner HP sensor [E] (1 screw).

22. Secure the scanner flat cable (1 screw).
23. Install the upper optics frame [F] (9 screws).

A095/A096/A097 5-30 FSM

[B]

[A]

TP504 TP504
[B]
TP512

TP514

24. Turn on the main switch and perform the scanner free run for about 5
minutes to break in the wires and to confirm correct scanner movement
as follows:

- Scanner Free Run -

1. Remove the air inlet duct [A] (1 screw).

Replacement &
Adjustment
2. Remove CN502, CN503, CN504 from the optic control Board [B].
3. Short-circuit TP514 and TP504(GND) on the optics control Board.
4. Turn on the main switch.
5. Short-circuit TP512 and TP504(GND), then the machine
automatically starts the scanner free run.
6. Turn off the main switch.

25. After performing the scanner free run, check the second scanner
alignment, then the first scanner alignment.
26. Perform the scanner control adjustment. (Refer to Scanner Control
Adjustment.)
27. Check the copy image.

FSM 5-31 A095/A096/A097

2.8 SCANNER CONTROL ADJUSTMENT

[B]
LED 501
[A]

Perform this adjustment under any one of the following conditions:

After the scanner motor replacement

After the scanner wire replacement
After the scanner timing belt replacement
After replacing the optics control Board

1. Perform the free run ( 2 Test Mode – PAGE 1) 30 times.

2. After the free run is completed, turn the rotary dip switch [A] until LED
501 [B] turns on.
NOTE: If this adjustment is improper, the timing between the scanner
and the paper feed will be also improper, causing paper jams at
the registration roller, or causing scanner noise due to wire
vibration.

A095/A096/A097 5-32 FSM

2.9 THIRD SCANNER REMOVAL

[A]

[B]

[E] [C]

Replacement &
Adjustment
[E] [D]

1. Remove the exposure glass. (Refer to Exposure Glass Removal.)

2. Remove the upper cover [A]. (Refer to Upper Cover Removal.)
3. Remove the lens unit cover [B] (2 screws).
4. Remove the two screws [C] fixing the front third scanner bracket.
5. Remove the sixth mirror [D].
6. Remove the third scanner [E] as shown.

FSM 5-33 A095/A096/A097

2.10 THIRD SCANNER DRIVE MOTOR / HP SENSOR
REPLACEMENT

[C]
[B]

[A]

[E]
[I]

[D]

[G]
[H]

[F]

1. Remove the third scanner unit. (Refer to the Third Scanner Removal.)
2. Open the right front cover then remove the shutter cover [A].
3. Remove the shutter inner cover [B] (1 screw).
4. Open the toner bottle [C] and close the toner hopper cover [D].
5. Remove the third scanner drive unit [E] (3 screws [F]).
6. Replace the third scanner drive motor [G] (1 connector, 2 screws).
7. Remove the third scanner HP sensor [H] with the bracket [I] (1 screw).
8. Replace the third scanner HP sensor (1 screw).

A095/A096/A097 5-34 FSM

2.11 LENS HORIZONTAL DRIVE BELT REMOVAL
[A]

[B]

[C]

Replacement &
Adjustment
[D]
[E] [F]

1. Remove the lens unit cover [A] and light shielding plate [B]. (Refer to
Scanner Drive Wires Replacement.)
2. Remove the light shielding mylar bracket [C] (1 screw).
NOTE: When re-installing the mylar bracket [C], be sure not to create
any gap between the bracket and the lens cover.
3. Remove the flat cable bracket [D] (1 screw, 2 connectors).
4. Position the roller [E] underneath the bracket [F].

FSM 5-35 A095/A096/A097

[A]

[E]
[F]
[C]

[D]

[D]
[B]

5. Remove the lens unit [A] (2 screws).

6. Loosen the tension pulley bracket [B] (1 screw).
7. Push the pulley bracket to the front then unhook the timing belt [C].
8. Remove the two timing belt holders [D] (1 screw each).
NOTE: When setting the timing belt, align the end [E] of the timing belt
to the edge [F] of the belt holder.

A095/A096/A097 5-36 FSM

2.12 LENS VERTICAL DRIVE BELT REMOVAL

[A]

[B]

[D] [C]

Replacement &
1. Remove the third scanner drive unit. (Refer to Third Scanner Drive Motor

Adjustment
Replacement.)
2. Remove the front bracket [A]. (Refer to Scanner Drive Wires
Replacement.)
3. Remove the lens unit [B]. (Refer to Lens Horizontal Drive Belt
Replacement.)
4. Loosen the two screws [C] fixing the tension pulley bracket [D].
5. Push the tension pulley bracket to the left (front view) then unhook the
timing belt.

FSM 5-37 A095/A096/A097

2.13 ORIGINAL SIZE SENSORS (2 LENGTH SENSORS, 1
WIDTH SENSOR)

[C]

[B]

[A]
[C]

[B]

[C]

1. Remove the exposure glass. (Refer to Exposure Glass Removal.)

2. Remove the lens unit cover [A] (2 screws).
3. Remove the original size sensor covers [B] (1 screw each).
4. Replace each original size sensor [C] (1 screw, 1 connector each).

A095/A096/A097 5-38 FSM

3. DEVELOPMENT AND TONER SUPPLY
3.1 DEVELOPMENT UNIT REMOVAL

[C]

[D]

[E] [A]

[A]
[B]
[G]

[F]

& Adjustment
Replacement
[H]
1. Turn off the main switch.
2. Open the front doors.
3. Remove the shutter cover [A] by releasing the hook [B].
NOTE: Be sure to move the lever [C] until it contacts part [D] (fully to the
front).
4. Remove the shutter inner cover [E] (1 screw).
5. Open the toner bottle holder [F].
NOTE: To open the toner bottle holder completely, while lowering the
shutter lever [G], push the bracket [H] to the right.

FSM 5-39 A095/A096/A097

[A]

[B]

[C] [D]

[F]

[G]

[E]

6. Close the toner hopper cap [A].

7. Remove the screw [B] fixing the drum stay [C].
8. Remove the drum stay knob [D] then take out the drum stay.
9. Disconnect the two connectors [E].
10. Pull out the development unit [F].
NOTE: 1. To prevent drum scratches, push the development unit to the
right while pulling it out.
2. When installing the development unit, do not forget to set the
two connectors [E].
3. When installing the drum stay, be careful not to pinch the
harness. Also, keep the harness away from gears.
4. When pulling out the development unit, do not hold the knob
[G].

A095/A096/A097 5-40 FSM

3.2 DEVELOPER REPLACEMENT

[B]

[C]

[A]

& Adjustment
Replacement
[D]

1. Take out the development unit. (Refer to Development Unit Removal.)

2. Place the development unit on the sheet [A] included with new developer.
3. Remove the two screws [B] fixing the toner hopper [C].
4. Turn the toner hopper 90 degree, then move it up to remove it from the
development unit.
5. Turn over the development unit then turn the paddle roller knob [D] to
empty developer onto the sheet. (The one way clutch in the knob [D]
allows turning the paddle roller counterclockwise only.)
NOTE: Dispose of used developer according to local regulations.

Make sure that no developer remains on the development rollers or in the

development unit.

FSM 5-41 A095/A096/A097

[A]

[B]

[A]
[B]
[C] [D]

[C]

[E]

6. Clean the side seals [A] and entrance seal [B].

NOTE: Cover the sleeve rollers with a sheet of paper [C] to prevent the
used developer being attracted to the sleeve rollers.
7. Evenly pour in one pack of developer [D] while turning the knob [E].
8. Re-install the toner hopper, then re-assemble the machine.
NOTE: Be sure to set to connectors after installing the development unit
in the machine.
9. Turn on the main switch, then perform developer initial setting
( 1 SP Adjustment – PAGE.1).

CAUTION: Never make any copy with the new developer before
completing the developer initial setting, otherwise toner
density control will be abnormal.

NOTE: If the developer initial setting is not completed, you cannot exit
the SP mode by pressing the "Quit" key. If this occur turn the
main switch off and on, then perform the initial setting again. If
the result is the same, see the troubleshooting section "SC352"
(Page 6-9).

A095/A096/A097 5-42 FSM

3.3 DEVELOPMENT ROLLERS REPLACEMENT
[B]

[A]

[B]

[D]

[C]

& Adjustment
Replacement
1. Remove the developer. (Refer to Developer Replacement.)
2. Remove the developer entrance seal [A] (2 screws, 2 hooks).
3. Remove the front and rear side seals [B].
NOTE: When re-assembling the development unit, use new side seals
and align the edge of the side seals to the corner [C] and the
edge [D] as shown.

FSM 5-43 A095/A096/A097

[B]
[A]

[H]

[E]

[I]

[D] [C]
[G]
[F]

4. Remove the coupling gear [A] (1 screw).

NOTE: Be careful not to lose the pin [B].

5. Remove the gear [C] (1 E-ring), gear [D] (1 E-ring) and gear [E].

CAUTION: Do not touch the screws at [F] and [G].

If the screws at [F] are loosened, the doctor gap will be
improper.
If the screws at [G] are loosened, the photoconductor gap
and magnetic field angle will be improper.
If either of them become abnormal, toner density control
will be abnormal.

6. Remove the front roller holder [H] (1 screw and 2 E-rings) and rear roller
holder [I] (1 screw).

A095/A096/A097 5-44 FSM

7. Replace the sleeve rollers.
8. Re-assemble the development unit and set the developer, then
re-assemble the copier.

CAUTION: If the original developer (already used) is returned to the

development unit, do not perform the developer initial
setting.
If the new developer is set, never make any copy before completing the
developer initial setting ( 1 SP Adjustment – PAGE.1).

& Adjustment
Replacement

FSM 5-45 A095/A096/A097

3.4 TONER DENSITY SENSOR REPLACEMENT

[A]

1. Remove the developer. (Refer to Developer Replacement.)

2. Replace the TD sensor [A] (2 screws).
NOTE: Before installing the TD (Toner Density) sensor, clean the
development unit well so that no carrier particle remains in the
gap between the TD sensor and the development unit casing.

3. Install the new developer and perform the developer initial setting.

CAUTION: Never make any copy before completing the developer

initial setting.

A095/A096/A097 5-46 FSM

3.5 TONER BOTTLE DRIVE MOTOR REPLACEMENT
[D]

[A]

[C]

[E]

[B] [F]

& Adjustment
Replacement
[G]
[H]

[I]

1. Open the toner bottle holder [A] with the bracket [B]. (Refer to
Development Unit Removal.)
2. Remove the toner bottle [C].
3. Remove four screws then remove the toner bottle holder by unhooking
the hole [D] from the pin on the hinge.
4. Remove the toner receiver [E].
5. Remove the toner bottle drive motor assembly [F] (1 connector, 2
screws).
6. Remove an E-ring [G] and slide the gear [H] to access a screw.
7. Replace the toner bottle drive motor [I] (3 screws – M3 x 4).

FSM 5-47 A095/A096/A097

Rev. 8/29/97
4. DRUM UNIT
4.1 DRUM UNIT REMOVAL AND OPC DRUM REPLACEMENT

[B]

[D] [C]
[A]

1. Take out the development unit. (Refer to Development Unit Removal.)

2. Lower the transfer belt unit.
3. Take out the drum unit by holding the knob [A].
NOTE: Close the protective shutter [B] to protect the OPC drum from
light when the drum unit is left outside the machine for servicing.

4. Open the upper drum unit (2 screws [C]).

5. Replace the OPC drum. Then remove the drum protective sheet from the
new drum.
NOTE: When returning the drum unit to the copier, do not forget to open
the protective shutter [B].
If it is hard to completely set the drum unit in the machine
because the gear is disengaged, then push in the drum unit
while holding down the cleaning blade release knob [D].
⇒ 6. Turn on the main switch, then perform process control initial setting
( 1 SP Adjustment – PAGE.1).

A095/A096/A097 5-48 FSM

Rev. 8/29/97
4.2 QUENCHING LAMP REPLACEMENT
[A]
[B]

[D]

& Adjustment
Replacement
[C]
CN663

1. Remove the OPC drum. (Refer to Drum Unit Removal and OPC Drum
Replacement.)
NOTE: Wrap a protective sheet or a few sheets of paper around the
drum to protect it from light.
2. Slightly pull up the wires [A] on the quenching lamp, then insert the head
of the small flat head screw driver [B] between the quenching lamp and
the drum unit casing to release the hook [C] at the center of the
quenching lamp.
NOTE: Do not pull the wire too strongly.
3. Disconnect the connector [D].
4. Replace the quenching lamp.
⇒ 5. Turn on the main switch, then perform process control initial setting
( 1 SP Adjustment – PAGE.1).

FSM 5-49 A095/A096/A097

4.3 GRID PLATE / CHARGE WIRE / WIRE CLEANER
REPLACEMENT

[A]

[B] [G]

[H]

[C] [I] [F]

[D]

[E]

1. Take out the main charge corona [A] (1 screw, 1 connector).

2. Remove the grid plate [B] (1 plastic screw, 4 hooks).
NOTE: When installing the grid plate, do not tighten the plastic screw [C]
too strongly.
3. Remove the front grid terminal [D], then the front end block cover [E].
4. Remove the terminal spring [F].
5. Slide the rear grid terminal [G] to the rear and remove it, then remove the
rear end block cover [H].
6. Remove the charge corona wire [I].

A095/A096/A097 5-50 FSM

Rev. 8/29/97
[A]

[B]

[C]

[B]

& Adjustment
Replacement
7. Remove the wire cleaner [A] (1 snap ring).
8. Install the wire cleaner and the charge corona wire.
NOTE: Locate the joint part [B] of the wire in the rear end block as
shown.
Correctly set the wire between the wire cleaner pads.
Do not loosen the screw [C], otherwise the charge corona height
will change.
⇒ 9. Turn on the main switch, then perform process control initial setting
( 1 SP Adjustment – PAGE.1).

FSM 5-51 A095/A096/A097

4.4 ERASE LAMP AND DRUM POTENTIAL SENSOR
REPLACEMENT
[D]
[B]
① [C]
Front
Side

[A]
②

Rear
Side

[F]

[E]

1. Open the drum shutter [A].

2. While pushing the hook [B] to the front by using a small flat head screw
driver [C], move up the front side of the erase lamp [D] as shown.
3. Slide the erase lamp to the front to release the rear side of the erase
lamp from the drum unit casing.
4. Disconnect the connector [E].
NOTE: Before removing the drum potential sensor, set a few sheets of
paper between the sensor and the OPC drum to protect the
drum surface.
5. Replace the drum potential sensor [F].

CAUTION: After replacing the drum potential sensor, perform the

process control data initial setting.
( 1 SP Adjustment – PAGE.1)

A095/A096/A097 5-52 FSM

4.5 CLEANING BLADE REPLACEMENT

[A]

[C] [G]
[H]
①

[D]
②

[B]
③
[C]

[E]
[F]

1. Remove the OPC drum. (Refer to Drum Unit Removal and OPC Drum
Replacement.)
2. Remove the cleaning blade [A] (2 screws).
3. Clean the entrance seal [B], side seals [C] and cleaning brush [D].
NOTE: When a vacuum cleaner is used, to protect the electrical parts

& Adjustment
Replacement
from static electricity, disconnect the connector on the charge
power pack and remove the ID sensor as follows:
1) Disconnect the 12P connector on the charge power pack [E].
2) Remove the screw [F] and separate the upper and the lower drum
units.
3) Remove the pick-off pawl bracket [G] (2 screws).
4) Disconnect the connector [H].
5) While turning the bracket counterclockwise (front view), slide the
pick-off pawl bracket to the rear.

4. Install the new cleaning blade.

NOTE: Do not clean the edge of the cleaning blade with cloth, otherwise
it damages the edge and causes black lines on copy images.
Do not touch the edge of the new cleaning blade, if some setting
powder or toner on the blade edge is removed, apply toner there.
When installing the cleaning blade, do not pinch the side seals.

FSM 5-53 A095/A096/A097

4.6 CLEANING BRUSH REPLACEMENT

[C] [B]

[D]

[A]

1. Remove the cleaning blade. (Refer to Cleaning Blade Replacement.)

2. Remove the coupling gear [A] (1 screw).
3. Remove the grounding wire [B] (1 screw).
4. Remove the bushing [C].
5. Pull the cleaning brush shaft to the rear to release the cleaning brush [D],
then remove the cleaning brush.
NOTE: Do not touch the cleaning brush with oily hands.
After replacement, clean the ID sensor surface.

A095/A096/A097 5-54 FSM

Rev. 4/15/94
4.7 PICK-OFF PAWL REPLACEMENT

[C]
[G]
[D]

[A]
[B]

[F]

& Adjustment
Replacement
[H]

1. Remove the ID sensor board bracket [A] (2 screws).

[H]
2. Disconnect the ID sensor harness [B].
3. Remove the E-ring [C], then slide out the bushing [D] (1 screw) and collar
[E].
4. Fully slide the shaft [F] to the rear.
5. Replace the pick-off pawl [G].

NOTE: Do not forget to hook the tension spring [H].

After replacement, check that the pick-off pawls move smoothly.

FSM 5-55 A095/A096/A097

4.8 TONER COLLECTION COIL REPLACEMENT

[A]

[B]

[C]
[D]

NOTE: Before starting the procedure remove the drum unit and the transfer
belt unit to prevent toner from dropping in the machine.

1. Open the front doors then remove the toner collection bottle [A]
(1 push-lock [B]).
2. Remove the upper and lower rear covers. (Refer to Upper and Lower
Rear Covers Removal.)
3. Remove the tank cover bracket [C] (2 screws).
4. Remove the toner collection motor [D] (2 connectors, 2 screws).
NOTE: When re-installing the toner collection motor, be sure to set the 2
positioning pins in the holes on the machine rear frame.

A095/A096/A097 5-56 FSM

[A]

[D]

[E]

[E]

& Adjustment
Replacement
[B] [E] [C] [F]

[C]

5. Open the main control board [A] (2 screws).

6. Remove the pulley bracket [B] and the timing belt [C] (1 screw).
NOTE: When re-installing the timing belt [C], be sure that the belt is
correctly hooked on the four pulleys as shown.
7. Remove the belt tightener unit [D] (2 screws).
8. Remove the four screws [E] fixing the toner collection coil casing [F] to
the machine rear frame.

FSM 5-57 A095/A096/A097

[A]

[B]

[C]

[B] [D] [C]

9. Remove the upper right cover [A]. (Refer to Upper Right Cover Removal.)
10. Remove the pin [B] of the push-lock fixing the toner collection coil casing.
NOTE: When removing the push-lock pin [B], catch the pin with
needle-nose pliers [C] (accessing from the hole under the main
control board, as shown).
When re-setting the push-lock pin [B], hold the pin with needle-nose
pliers. Then, while holding the pin above the push-lock holder [D],
push the pin head down with you finger. Insert your finger from the
space below the LCT connector bracket, as shown.

A095/A096/A097 5-58 FSM

[B]

[C]

[A]
[D]

& Adjustment
Replacement
[F]
[E]

11. Remove the exhaust fan [A] (1 connector, 3 screws).

12. Remove the main motor [B] (1 connector, 4 screws).
13. Remove the toner collection coil casing [C] and put it on the sheet of
paper.
14. Disassemble the toner collection coil casing [D] (8 screws).
15. Remove the drive pulley [E] (1 E-ring).
16. Replace the toner collection coil [F].

FSM 5-59 A095/A096/A097

4.9 OZONE FILTER REPLACEMENT

[B]
[E]

[D]

[A]
[C]

[C]

1. Open the front doors and open the toner bottle holder.
2. Remove the transfer belt unit prop [A] (3 screws).
3. Replace the ozone filter [B].
NOTE: To install the transfer belt unit prop smoothly, set in order the
lower pins [C], drive roller shaft [D], and the upper pins [E].

A095/A096/A097 5-60 FSM

5. TRANSFER BELT UNIT
5.1 TRANSFER BELT UNIT REMOVAL/INSTALLATION

[F]
[D]
[A]

[G] [E]

[B]

& Adjustment
Replacement
- Removal - [C]

1. Turn off the main switch.

2. Remove the transfer belt unit prop [A] (3 screws).
3. Disconnect the connector [B].
4. While turning the lever [C] counterclockwise, take out the transfer belt
unit.
NOTE: 1) Do not touch the transfer belt with oily hands.
2) Take care not to scratch the OPC drum with part of the
transfer belt unit. Be careful when installing the transfer belt
unit.

- Installation -
1. While turning the lever [C] counterclockwise, install the transfer belt unit.
NOTE: 1) Insert the gear [D] in the hole [E] on the rear frame.
2) Place the slot [F] of the transfer belt unit on the rail [G].

FSM 5-61 A095/A096/A097

[C]

[B]

[E]

[A]

[D]

2. Install the transfer belt unit prop (3 screws).

NOTE: To install the transfer belt unit prop smoothly, set in order the
lower pins [A], drive roller shaft [B], and the upper pins [C].

3. After installation, confirm the following points:

1) Smooth up-down movement of the transfer belt unit,
2) Part [D] of the transfer belt unit is inside the drum stay,
3) Part [D] of the transfer belt unit is set in the dent [E] on the drum unit
casing.

A095/A096/A097 5-62 FSM

5.2 TRANSFER BELT REPLACEMENT
[C]
[A]

[B]

[D]

& Adjustment
Replacement
[D]
1. Take out the transfer belt unit. (Refer to Transfer Belt Unit Removal.)
2. While raising the knob [A], disconnect the two connectors [B].
3. Turn the transfer belt upper unit [C] 90 degrees counterclockwise, then
raise and remove it.
4. Remove the screws [D].

FSM 5-63 A095/A096/A097

Rev. 12/93

[H]

[D]

[A]

[G]
[C] [B]
[H]

[H]

[E]

5. Turn the belt drive roller holder [A] clockwise (front view).
6. Replace the transfer belt [B].
NOTE: 1) Before installing the transfer belt, clean both sides of the
transfer belt with a dry cloth (do not use alcohol).
2) Before installing the transfer belt, clean the following items
with alcohol.
• Belt drive roller [C]
• Belt roller [D]
• Bias roller [E]
• Discharge terminal [F]

3) Position the transfer belt at the center of the belt roller [D].
(Both marks [G] should be visible.)
4) Set the transfer belts inside the bias terminals [H].

A095/A096/A097 5-64 FSM

5.3 CLEANING BLADE REPLACEMENT
[A]

[B]

[C]

& Adjustment
Replacement
[D]

[E]
1. Remove the transfer belt. (Refer to Transfer Belt Replacement.)
2. Remove the cleaning blade [A] (2 screws).
3. Clean the seals [B].
NOTE: When using a vacuum cleaner, to protect the transfer power
pack from static electricity, remove the power pack as follows:
1) Disconnect two connectors [C].
2) While pushing the power pack toward the solenoid [D],
release the power pack from the hook [E].

4. Install the new cleaning blade.

NOTE: Do not touch the edge of the cleaning blade. If some of the
setting powder on the blade edge is removed, apply setting
powder or toner there.

FSM 5-65 A095/A096/A097

6. PAPER FEED
6.1 PAPER TRAY UNIT REMOVAL
[C]

[A] [C]

[B]

[C]

[C]

[E]

[D]

To facilitate transportation, the upper part of the copier (copier main frame)
[A] and the lower part of the copier (paper tray unit) [B] can be separated as
follows:
1. Turn off the main switch.
2. Remove the front covers. (Refer to Front Cover Removal.)
3. Remove the four screws [C].
4. Open the small rear cover [D] (1 screw).
5. Remove the five connectors [E].
6. Remove the copier main frame [A] from the paper tray unit [B].
NOTE: When re-installing the copier main frame on the paper tray unit,
do not pinch the harness between the copier main frame and the
paper feed unit.

A095/A096/A097 5-66 FSM

6.2 PAPER TRAY REMOVAL
- Tandem Tray Removal (1st tray of the A096 copier) -

[A]

[C]

[B]

[E]
[C]
[D]

Replacement &
[G]

Adjustment
[F]
[D]
1. Open the left door and draw out the tandem tray.
2. While pushing the release lever [A] to the right with the head of the screw
driver [B], slightly push the right tandem tray [C] to separate it from the
left tandem tray [D].
3. Remove the stopper [E] (1 screw).
4. Remove the left tandem tray [D] from the left guide Accuride [F] (2
screws).
5. While holding the right tandem tray [C] from the bottom, remove the right
tandem tray from the right guide Accuride [G] (2 screws).
NOTE: If two screws are removed without holding the right tandem tray,
it will drop.

FSM 5-67 A095/A096/A097

- Universal Tray / 550 sheet tray/ Built-in LCT Removal
(all trays of the A095 copier / 2nd, 3rd trays of the A096 copier) -

1. Draw out the tray.

2. Remove the tray from both guide Accurides as shown (4 screws).

A095/A096/A097 5-68 FSM

6.3 PAPER FEED ROLLERS REPLACEMENT

[B]

[A]

[E] [D] [C]

1. Turn off the main switch.
2. Remove the paper tray where the feed rollers belong to. (Refer to Paper
Tray Removal.)

Replacement &
3. Remove the pick-up roller [A] (1 snap ring).

Adjustment
4. Remove the feed roller [B] (1 snap ring).
5. Remove the snap ring [C] fixing the separation roller [D] then separate
the separation roller [D] from the torque limiter [E].

NOTE: 1) The paper feed (pick-up, feed, separation) rollers used in the 1st
~ 3rd feed units in the paper tray unit are different from the feed
rollers used in the by-pass feed table and 3.5K LCT.
2) Do not touch the surface of the rollers with oily hand.

FSM 5-69 A095/A096/A097

6.4 TANDEM REAR FENCE DRIVE BELT REMOVAL
(A096/A097 copier only)
[B]

[D]
[C]

[C]

[A]

[F]

[E] [G]

1. Draw out the tandem tray.

2. Separate the right tandem tray from the left tandem tray [A]. (Refer to
Tandem Tray Removal.)
3. Remove the rear fence [B] on the left tandem tray (2 screws).
4. Remove the rear base plate [C] with the rear fence drive motor [D] (3
screws).
NOTE: When re-installing the rear base plate, make sure that the
grounding plate [E] is attacked to the rear base plate.
5. Remove the end fence [F] (2 screws).
6. Remove the center bottom plate [G] (2 screws).

A095/A096/A097 5-70 FSM

[D]

[C]

[A]

[B]

7. Disconnect the three connectors [A].

8. Loosen the tightener screw [B] and unhook the tension spring [C].
9. Remove the timing belt [D].
NOTE: When installing the timing belt, hook the spring [C] then, tighten

Replacement &
the screw [B].

Adjustment

FSM 5-71 A095/A096/A097

6.5 TANDEM SIDE FENCE MOTOR REMOVAL
(A096 copier only)
[D]
[H]

[F] [F]
[A]
[E]
[B]

[C]

[A]

[I]

[G]
1. Open the side fences [A] and raise the bottom plate [B] of the right
tandem tray.
2. Remove the lift arm [C] (2 screws).
3. Remove the cover [D] (1 screw).
4. Remove the bracket [E] (2 screws [F]).
5. Remove the side fence drive motor [G] (2 screws [H] and 2 nuts).
NOTE: When installing the side fence drive motor, move both side
fences to the innermost position, then set the motor gear
between the two rack gears [I].

A095/A096/A097 5-72 FSM

6.6 PAPER FEED TIMING ADJUSTMENT
6.6.1 Paper Feed Timing Adjustment FT6645/6655 (A095/A096) Only

[C]

[A]

[B]
10 mm

[D]

10 ± 5 mm

1) Paper feed timing adjustment for the 1st feed station

1. Place a white paper on the exposure glass so that there is a gap of 10
mm between the white paper [A] and the left scale [B].

Replacement &
Adjustment
2. Enter SP mode (refer to Service Program Access Procedure) and access
the 1 SP Adjustment – PAGE 2.

3. Touch the "Copy in SP" key [C] then select the 1st feed station.
4. Enter a copy quantity of "2" using the number keys.
5. Touch the "SP Mode" key.
6. Press the Start key and evaluate the width of the white area [D] on the
copy. The adjustment standard is 10 ± 5 mm.

NOTE: In this mode, the registration roller does not stop for registration.
Do not make copies in "Copy in SP" mode for this adjustment. In
"Copy in SP" mode, the registration clutch stops normally.

FSM 5-73 A095/A096/A097

Rev. 7/94

[A]
[B]
[C]

[D]

7. For the first copy, touch the – key [A] or the + key [B] to adjust the white
area width.
8. For the second copy, touch the – key [C] or the + key [D] to adjust the
white area width.
9. Repeat steps 6 to 8.

NOTE: Concerning the adjustment for the 1st feed station, it is necessary to
adjust the feed timing for the 1st and 2nd sheets individually.

2) Paper feed timing adjustment for the 2nd, 3rd feed stations, the LCT
and duplex unit. (A095/A096/A097 Copiers)

Refer to Paper Feed Timing Adjustment for the 1st feed station. Eliminate
steps 4 and 8.

A095/A096/A097 5-74 FSM

6.6.2 Paper Feed Timing Adjustment FT6665 (A097) Only
[C]

[A]

[B]
10 mm

[E]

[D]
[F]

10 ± 5 mm
1-1) Paper feed timing adjustment for the 1st, 2nd, 3rd feed stations,
the
LCT and duplex unit (A097 copier)
1. Place a sheet of white paper on the exposure glass so that there is a gap
of 10 mm between the white paper [A] and the left scale [B].
2. Enter SP mode (refer to Service Program Access Procedure) and access

Replacement &
Adjustment
the SP Adjustment – PAGE 2.
3. Touch the "Copy in SP" key [C] then select the 1st feed station.
4. Touch the "SP Mode" key.
5. Press the Start key and evaluate the width of the white area [D] on the
copy. The adjustment standard is 10 ± 5 mm.
NOTE: In this mode, the registration roller does not stop for registration.
Do not make copies in "Copy in SP" mode for this adjustment. In
"Copy in SP" mode, the registration clutch stops normally.
6. Touch the – key [E] or the + key [F] to adjust the white area width.
7. Repeat steps 5 to 6.
NOTE: Adjustment procedure for the 2nd, 3rd, by-pass, duplex and
large capacity trays continues on page 5-74.

FSM 5-74 A A095/A096/A097

Rev. 7/94

This page intentionally left blank.

A095/A096/A097 5-74 B FSM

Rev. 12/93
[A]
[C] [E]

[F]

[D]

[B]
[G]

[H]

NOTE: In this mode the

registration rollers
DO stop for
registration.
3) Paper feed timing adjustment for the by-pass feed station
1. Set two sheets of paper on the by-pass feed table [A].
2. Enter SP mode (refer to Service Program Access Procedure) and access

Replacement &
1 SP Adjustment – PAGE 2.

Adjustment
3. Touch the "Copy in SP" key [B].
4. Select the by-pass feed station.
5. Press the start key then when the paper stops for registration, mark the
trailing edge [C] of the paper on the next paper as shown.
6. Measure the distance [D] between the leading edge of the mark [E] and
the trailing edge of the paper [F] as shown. The adjustment standard is
106 ~ 115 mm.
7. Touch the "SP Mode" key.
8. Touch the – key [G] or the + key [H] to adjust the distance [D].
9. Touch the "Copy in SP" [B].
10. Repeat steps 5 to 9.

FSM 5-75 A095/A096/A097

Rev. 4/15/94
6.7 PAPER FEED CLUTCH REMOVAL

[B]

[A]

[D]

[E]

[C]

1. Turn off the main switch then open the right front door and remove the
push-lock [A].
2. Remove the toner collection bottle [B].
NOTE: If the LCT is installed, remove it from the copier.
3. Remove the lower right cover [C]. (Refer to Lower Right Cover Removal.)
4. Remove the upper then the lower vertical transport guides [D] and [E].

A095/A096/A097 5-76 FSM

Rev. 4/15/94
[B] [A]

[A]

[F] [H]

[G]

[I]

[D]

Replacement &
Adjustment
[E] [C]

5. Remove the knobs [A] (1 screw each) then remove the right inner cover
[B] (2 screws).
6. While holding the shaft [C] with an Allen key, remove the fixing screw [D],
then remove the knob [E].
7. Remove the magnet [F].
8. Pull out all paper trays then remove the paper tray unit inner cover [G] (2
screws).
9. Remove the two connectors [H].
10. Remove the support bracket [I] (1 screw).
NOTE: The support bracket is used only for the first feed station.

FSM 5-77 A095/A096/A097

Rev. 4/15/94

[C] [A] [B]

[H]

[D]

[E]
[D]
[F]
[G]

11. Fully draw out the paper tray.

12. Remove the two screws [A] fixing the tray feed unit [B].
13. Disconnect the connectors [C].
14. Remove the tray feed unit.
15. Loosen the two Allen screws [D].
16. Remove the tray feed clutch [E] (1 connector).
NOTE: When re-installing the tray feed clutch, set the stopper [F] of the
clutch on the edge of the bracket [G] then fully push in the clutch
on the feed roller shaft [H] and secure the Allen screws [D].

A095/A096/A097 5-78 FSM

6.8 BY-PASS FEED TABLE REMOVAL

[A]

[B]

[B]

1. Remove the right inner cover. (Refer to Right Inner Cover Removal.)
2. Remove the total counter with bracket (1 screw, 1 connector).
3. Loosen the Allen screw [A] on the hinge.

Replacement &
Adjustment
4. Remove the hinge pin [B] (1 screw).
5. Remove the by-pass feed table (1 connector).

FSM 5-79 A095/A096/A097

6.9 BY-PASS FEED ROLLERS REPLACEMENT

[A]

[C] [B]

1. Open the by-pass feed table then remove the cover [A] (3 screws).
2. Replace the pick-up roller [B] (1 snap ring) and the feed roller [C] (1 snap
ring).

NOTE: The paper feed (pick-up, feed, separation) rollers used in the
by-pass feed table and LCT are different from the paper feed rollers
used in the 1st ~ 3rd feed units in the paper tray unit. They are not
interchangeable.

A095/A096/A097 5-80 FSM

[A]

[B]

Replacement &
3. Remove the feed unit cover [A] as shown.

Adjustment
4. Replace the separation roller [B] (1 snap ring).

FSM 5-81 A095/A096/A097

6.10 BY-PASS PAPER SIZE SENSOR REPLACEMENT

[B]

[D]

[C] [A]

1. Turn off the main switch.

2. Open the by-pass table and remove the feed unit cover. (Refer to Feed
Unit Cover Removal.)
3. While pushing the hook [A] with the head of the flat head screw driver as
shown, remove the table assembly [B] (2 screws, 1 connector [C]).
4. Remove the by-pass paper size sensor [D] (2 screws).

A095/A096/A097 5-82 FSM

[B]

[A]

[C]

[B]
5. Re-install the by-pass paper size sensor then reassemble the by-pass
feed table.
NOTE: When installing the table assembly, route the wires [A] correctly
as shown.
The paper guides [B] must be in the lower position as shown.
6. Perform the by-pass feed sensor paper size correction ( 1 SP
Adjustment mode – PAGE 9) as follows:
1) Enter SP mode (refer to Service Program Access Procedure) then
access 1 SP Adjustment mode – PAGE 9.

Replacement &
2) Place the side fence [C] at the A4 or 81/2 x 11 sideways position

Adjustment
according to the paper size decal on the table.
3) Place the side fence [C] at the A6 or 41/2 x 51/2 lengthwise position
according to the paper size decal on the table.

FSM 5-83 A095/A096/A097

6.11 BY-PASS FEED CLUTCH REMOVAL
[B]

[A]

[C]

1. Remove the upper rear cover [A]. (Refer to Upper Rear Cover Removal.)
2. Lower the main control board [B] (2 screws).
3. Unhook the main control board bracket hinge [C].

A095/A096/A097 5-84 FSM

[A]

[D]

[C]

[E]

[B]

Replacement &
Adjustment
4. Remove the by-pass feed motor [A] (2 screws).
5. Remove the clutch stopper [B] (1 screw).
NOTE: When re-installing the by-pass feed clutch [C], set the pin [D] of
the clutch in the cutout [E] of the stopper.
6. Remove the by-pass feed clutch (1 connector).

FSM 5-85 A095/A096/A097

6.12 REGISTRATION CLUTCH REMOVAL

[B]

[C]

[D]

[A]

[E]

[F]

1. Lower then unhook the main control board bracket hinge. (Refer to
By-Pass Feed Clutch Removal.)
2. Remove the clutch stopper [A] (1 screw).
NOTE: When re-installing the registration clutch [B], set the pin [C] of
the clutch in the cutout of the stopper [D].
3. Loosen the Allen screw [E].
4. Remove the registration clutch (1 connector).
NOTE: When re-installing the registration clutch, fully push in the clutch
on the registration roller shaft [F] and secure the Allen screw.

A095/A096/A097 5-86 FSM

6.13 PAPER DUST CLEANER REMOVAL

[B]

[A]

[B]
1. Remove the development unit. (Refer to Development Unit Removal.)
2. While pushing down the hook lever [A], remove the paper dust cleaner
[B].
3. Remove paper dust inside the paper dust cleaner and clean the inside of
the cleaner with a dry cloth or a blower-brush.

Replacement &
Adjustment

FSM 5-87 A095/A096/A097

6.14 REGISTRATION SENSOR REMOVAL

[C]

[A]

[B]
[D]
1. Remove the right inner cover [A]. (Refer to Right Inner Cover Removal.)
2. Disconnect the connector [B].
3. Pull out the registration sensor assembly [C].
4. Clean the photo sensor [D] with a blower-brush.

A095/A096/A097 5-88 FSM

6.15 COPIER FEED UNIT REMOVAL

[D] [B]

[A]

[C]

Replacement &
Adjustment
1. Remove the development unit. (Refer to Development Unit Removal.)
2. Remove the right inner cover. (Refer to Right Inner Cover Removal.)
3. Remove the by-pass feed motor. (Refer to By-pass Feed Clutch
Removal.)
4. Remove the three connectors [A] for the guide plate positioning solenoid,
registration clutch, and the pick-up solenoid.
NOTE: Before disconnecting the connectors, make sure to identify
them. Some of the connectors use identical pin leads but they
are not interchangeable. Take special care not to misconnect
the positioning solenoid and registration clutch connectors.
5. Remove the upper right cover [B] and the paper feed unit cover [C].
6. Disconnect the three connectors [D].
7. Draw out the duplex unit about 10 cm.

FSM 5-89 A095/A096/A097

[D]

[A]

[C]

[B]

8. Remove the registration roller knob [A] (1 screw).

9. Remove the copier feed unit [B] (4 screws).
NOTE: When installing the copier feed unit to the copier:
1) Do not pinch the harness.
2) Keep the duplex unit drawn out.
3) Fit the two cut outs [C] to the pins [D].

A095/A096/A097 5-90 FSM

6.16 TANDEM FEED TRAY PAPER SIZE CHANGE
NOTE: 1. At the factory, all paper trays (1st, 2nd and 3rd) are set as A4
sideways. At the customer’s request, change the paper size as
follows.
2. For the 550 sheet fixed paper tray and the 1500 sheet built-in
LCT, refer to the installation procedure section.

[B] [B]

[A]

[C]

Replacement &
[B]

Adjustment
- Used as tandem tray for A4 sideways or smaller size paper -
1. Draw out the tandem tray [A].
2. Remove the rear and front side fences [B] (one screw and one pushlock
each) on the right tandem tray.
3. Re-position the end fences [C] on both rear and front side fences (1
screw each) according to the paper size.

FSM 5-91 A095/A096/A097

[A]

[B]

[E] [D]
[C]

[A]

4. Re-install both side fences [A] to the appropriate position according to

the paper size, as shown.
NOTE: The position of the side fence holders [B] and the pins [C] on the
lack gear differs according the paper size (from the outside pin:
A4, 11", B5).
5. Change the position of the front and rear side fences [D] (2 screws each)
and end fence [E] (2 screws) on the left tandem tray according to the
paper size.
6. Enter SP mode (refer to Service Program Access Procedure) and access
4 SP Special Features – PAGE 5.

7. Select the appropriate paper size according to position of the side and
end fences.

A095/A096/A097 5-92 FSM

[C]
[C]

[A]
[A]

[B]

Replacement &
- Used as fixed tray for paper longer than A4/Letter sideways -

Adjustment
1. Draw out the tandem tray.
2. Remove the rear and the front side fences [A] (1 screw and 1 push-lock
pin each) on the right tandem tray.
3. Remove the end fences [B] on both the rear and the front side fences (2
screws each).
NOTE: It is not necessary to re-install the end fences.
4. Install both side fences to the appropriate position according to the paper
size (one screw and one lock pin for each side fence).
NOTE: Support plates [C] are used only for A4, B5, and letter
lengthwise sizes.
Keep the end fences and support plates for future use.

FSM 5-93 A095/A096/A097

[B]

[A] [A]

5. Change the position of the front and rear side fences [A] (2 screws each)
and end fence [B] (2 screws) of the left tandem tray according to the
paper size.
6. Enter SP mode (refer to Service Program Access Procedure) and access
4 SP Special Features – PAGE 5.

7. Select the appropriate paper size according to the side and end fences
position.

A095/A096/A097 5-94 FSM

6.17 UNIVERSAL TRAY PAPER SIZE CHANGE
At the factory, the universal paper tray is set as A4/81/2" x 11" sideways.
Normally, paper size is changed by the customer by following the operating
instructions.
Only when the customer needs the A5/51/2" x 81/2" lengthwise paper size
does a service representative need to change the paper size. In this case,
proceed as follows:
[A]

Replacement &
1. Install the front and rear side fences [A] (2 screws).

Adjustment
NOTE: These side fences are the same as the side fences used in the
550 sheet fixed paper tray.
These side fences are options, order them as service parts.

FSM 5-95 A095/A096/A097

7. FUSING UNIT
7.1 FUSING UNIT REMOVAL
[B]

[A]

1. Turn off the main switch.

2. Open the left front door.
3. Remove the stopper [A] (1 screw).
4. While releasing the lever [B], pull out the fusing unit as shown.
NOTE: Hold the bottom of the fusing unit as shown.

A095/A096/A097 5-96 FSM

7.2 FUSING THERMISTOR REPLACEMENT

[B]

[C]

[A]

[D]

[E]

Replacement &
Adjustment
1. Remove the fusing unit. (Refer to Fusing Unit Removal.)
2. Remove the knob [A] (1 screw).
3. Remove the two screws fixing the fusing front cover [B].
4. Pull the lever [C] then lower the cover [B] to unhook the fusing unit.
5. Remove the fusing unit upper cover [D] (1 screw).
6. Replace the thermistor [E] (1 screw, 1 connector).
NOTE: When re-assembling the fusing unit, secure the harness in the
clamps correctly.
Apply a little silicone oil at the thermistor’s point of contact with
the hot roller.

FSM 5-97 A095/A096/A097

Rev. 7/94
7.3 FUSING THERMOFUSE REPLACEMENT
7.3.1 Fusing Thermofuse Replacement FT6645/6655 (A095/A096) Only

[B]
[C]

[B]

[A]

1. Remove the fusing unit upper cover. (Refer to Fusing Thermistor

Replacement.)
2. Remove the terminal bracket [A] (2 screws, 1 hook).
3. Disconnect the two connectors [B].
4. Replace the fusing thermofuse [C] (1 screw).
NOTE: When re-assembling the fusing unit, secure the harness in the
clamps correctly.

A095/A096/A097 5-98 FSM

Rev. 7/94
7.3.2 Fusing Thermofuse Replacement FT6665 (A097) Only

[B] [C]

[B]

[A]

1. Remove the fusing unit upper cover. (Refer to Fusing Thermistor

Replacement.)

Replacement &
2. Remove the terminal bracket [A] (2 screws, 1 hook).

Adjustment
3. Disconnect the three connectors [B].
4. Replace the fusing thermofuse [C] (1 screw).
NOTE: When re-assembling the fusing unit, secure the harness in the
clamps correctly.

FSM 5-98 A A095/A096/A097

Rev. 7/94
7.4 FUSING LAMP REPLACEMENT
7.4.1 Fusing Lamp Replacement FT6665 (A097) Only
[E]

[D]

[C]’
[C]

[B] [B]’ [F]

[G]

[G] [H]

[A]

[H]

1. Remove the fusing unit. (Refer to Fusing Unit Removal.)

2. Remove the terminal bracket [A] (2 screws).
3. Disconnect the front connectors [B] and [B]’ and the rear connector [C]
and [C]’.
4. Remove the front fusing lamp holder [D] and the rear fusing lamp holder
[E] (1 screw each).
5. Replace the fusing lamps [F].
NOTE: Locate the green connectors [C] of the fusing lamp to the rear
side.
Set the connectors from the fusing lamps (green) [G] and from
the thermofuse (white) [H] in the correct position on the terminal.

A095/A096/A097 5-98 B FSM

Rev. 7/94
7.4.2 Fusing Lamp Replacement FT6645/6655 (A095/A096) Only

[E]

[D]
[C]

[B] [F] [G]

[H] [A]

Replacement &
Adjustment
1. Remove the fusing unit. (Refer to Fusing Unit Removal.)
2. Remove the terminal bracket [A] (2 screws).
3. Disconnect the front connector [B] and the rear connector [C].
4. Remove the front fusing lamp holder [D] and the rear fusing lamp holder
[E] (1 screw each).
5. Replace the fusing lamp [F].
NOTE: Locate the yellow connector [C] of the fusing lamp to the rear
side.
Set the connectors from the fusing lamp (yellow) [G] and from
the thermofuse (white) [H] in the correct position on the terminal.

FSM 5-99 A095/A096/A097

7.5 HOT ROLLER REPLACEMENT

[A]

[C]

[D]

[B]

1. Remove the fusing lamp [A]. (Refer to Fusing Lamp Replacement.)

2. Lower the fusing exit assembly [B].
3. Remove the upper stay [C] (4 screws).
4. Remove the oil supply roller unit [D] (1 lever) (Refer to Oil Supply Roller
Replacement).

A095/A096/A097 5-100 FSM

[G] [D]

[C]
[E]
[F]

[C]

[B]

[A]
[G]
[E] [F]
5. Lower both side pressure spring holders [A] by using the screw driver [B]
as a lever.
6. Remove the front and rear C-rings [C], gear [D], antistatic spacers [E]
isolating bushings [F] and bearings [G].
NOTE: When installing a new fusing roller:
1) Lubricate the inner and the outer surface of the isolating
bushings [F] with BARRIERTA L55/2 grease.

Replacement &
Adjustment
2) Lubricate the fusing drive gears and their shafts with grease
G501.
3) Peel off 3 cm (1 inch) form both ends of the protective sheet,
and install the hot roller.
Before applying fusing pressure, remove the rest of the
protective sheet.

FSM 5-101 A095/A096/A097

7.6 PRESSURE AND BEARING ROLLER REPLACEMENT

[B]
[C]

[C]

[A]

1. Remove the hot roller. (Refer to Hot Roller Replacement.)

2. Remove the lower fusing entrance guide [A] (2 screws).
3. Lift the pressure roller [B] and remove it.
4. Replace pressure roller and bearings [C].
NOTE: When installing a new pressure roller:
1) Lubricate the roller shaft and the inner surface of the bearings
with BARRIERTA L55/2 grease.
2) Lubricate the fusing drive gears and their shafts with G501
grease.
5. Re-assemble the machine.

A095/A096/A097 5-102 FSM

7.7 FUSING STRIPPER PAWL REPLACEMENT

[D] [A]

[E]
[B]

[C]

[A]

[F]

Replacement &
Adjustment
[F]

1. Turn off the main switch and pull out the fusing unit.
2. Lower the fusing exit assembly [A].
3. Remove the two screws (the front screw [B] is a stepped screw) fixing
the upper exit guide [C].
4. Unhook the spring [D] then replace the strippers [E].
NOTE: After setting the fusing stripper pawl, confirm that the strippers
are correctly held by the stripper holders [F] as shown.
If not, remove the stripper and bend the holders [F] inward.
Apply the grease-Barrierta L55/2 on the inner surface of the
holder [F].

FSM 5-103 A095/A096/A097

7.8 FUSING PRESSURE ADJUSTMENT

Rear

[A]

Front

[B]

NIP BAND WIDTH ADJUSTMENT STANDARD: 8.1±0.8mm (A095/A096copiers)

10.0 ± 0.5 mm (A097 copier)

1. Make a black copy (sky shot, A3 / Double Letter paper).

2. As soon as the paper starts to exit, open the left door to stop the paper in
the fusing unit.
3. Wait about 20 seconds, then turn the fusing knob quickly to deliver the
paper.
4. Measure the nip band width [A] at the center.
5. If the nip band width is not within adjustment standards, change the
spring hook position [B].

A095/A096/A097 5-104 FSM

Rev. 4/15/94
7.9 PAPER EXIT UNIT REPLACEMENT
- Removal -

[B]

[D]

[A]

Replacement &
Adjustment
[C]

1. Remove the upper left cover. (Refer to Upper Left Cover Removal.)
2. Draw out the duplex unit [A].
3. Remove the lever bracket [B] (2 screws).
4. Disconnect the two connectors [C].
5. Take out the paper exit unit [D] (4 screws).
NOTE: Place the paper exit unit so that the paper exit roller comes to
the bottom to prevent the brush roller from being pressed and
damaged.

FSM 5-105 A095/A096/A097

- Installation -

[B]
[D]

[F]
[A]

[C]

[E]
1. Set the paper exit unit in the following order:
1) Set the drive shaft [A] on the left rail [B].
2) Set the plate [C] on the right rail [D].
3) Set the positioning pin [E] in the hole [F].

2. Install the paper exit unit (2 connectors, 4 screws).

3. Re-assemble the copier.

A095/A096/A097 5-106 FSM

Rev. 7/94
7.10 OIL SUPPLY/OIL SUPPLY CLEANING ROLLER
REPLACEMENT (A097)

[A]

[C]
[H]
[G]
[B] [I] [F]

[D]
[H]
[G] [E]

Replacement &
Adjustment
[F]
[D]

1. Pull out the fusing unit.

2. Lower the lever [A].
3. Remove the oil supply unit [B].
4. Remove the upper entrance guide [C] (1 screw).
5. Loosen screws [D], then remove the cleaning roller [E].
6. Install two bushings [F] on the new cleaning roller.
7. Remove the spring [G].
8. Remove the bushing [H].
9. Install the new oil supply roller [I] then reassemble the unit.
NOTE: While pressing down the lever [A], install the oil supply unit.

FSM 5-106 A A095/A096/A097

Rev. 7/94
7.11 PRESSURE ROLLER CLEANING ROLLER
REPLACEMENT (A097 Copier)

[A]

[B]

[D]

[D]
[C]
1. Pull out the fusing unit.
[E]
2. Remove the bottom plate [A]
(1 screw). [C]

3. Remove the cleaning roller unit [B] (2 screws).

4. Remove the brackets [C] (1 screw each).
5. Remove the bushings [D] (1 E-ring each).
6. Replace the cleaning roller [E].
NOTE: Since the spring pressure (plate springs on the brackets [C]) is
stronger than the A095/A096 copier’s cleaning roller, there is no
interchangeability between A095/A096 and A097 cleaning roller
unit.
7. Reassemble the unit.

A095/A096/A097 5-106 B FSM

7.10 OIL SUPPLY ROLLER REPLACEMENT

[A]

[B]

[E]

1. Pull out the fusing unit.

2. Lower the lever [A].
3. Remove the oil supply unit [B].
4. Remove the spring [C].
5. Remove the bushing [D].
[D]

Replacement &
6. Replace the oil supply roller [E].

Adjustment
7. Reassemble the unit. [C]

NOTE: While lowering the lever [A], install the oil supply unit.

FSM 5-107 A095/A096/A097

7.11 CLEANING ROLLER REPLACEMENT

[A]

[B]

[E]
[F]

[D]
[F]
1. Pull out the fusing unit.
[E]
2. Remove the bottom plate [A] (1 screw). [C]
3. Remove the cleaning roller unit [B] (2 screws).
4. Remove the bracket [C] (1 screw).
5. Remove the cleaning roller [D].
6. Remove the seals [E] and bushings [F] from both sides of the cleaning
roller, then install them to the new cleaning roller.
7. Reassemble the unit.

A095/A096/A097 5-108 FSM

8. DUPLEX UNIT
8.1 FEED ROLLER REPLACEMENT

[A]

[C] [B]
[D]

Replacement &
Adjustment
[E]

1. Open the front doors and draw out the duplex unit.
2. Remove the duplex front cover [A] (3 screws).
3. Slide the lever [B] to the rear then open the duplex reverse assembly [C].
4. Remove the lower separation guide plate [D] (2 screws).
5. Remove the snap ring [E].

FSM 5-109 A095/A096/A097

[A]
[E]

[D]

[C]
[B]

6. Remove the harness bracket [A] (1 screw).

7. Remove the gear [B] (1 E-ring).
8. Remove the bushing [C] (1 E-ring).
9. Slide the feed roller shaft [D] to the rear then slide the feed roller [E] to
the front and replace it as shown.

A095/A096/A097 5-110 FSM

8.2 SEPARATION BELTS REPLACEMENT

[B]

[A]

[F]

[E]
[D]
[C]

Replacement &
Adjustment
[G]
1. Open the front doors and draw out the duplex unit.
2. Remove the gear [A] (1 E-ring).
3. Remove the bracket [B] (1 screw) then remove the gear [C].
4. Remove the gear [D] and the bushing [E] (1 E-ring).
5. Remove the separation belt unit [F].
6. Remove the guide mylar [G] (2 snap rings).

FSM 5-111 A095/A096/A097

[D]

[A]

[B]

[G]

[F] [E]

7. Remove the bushing [A] (1 snap ring). [H]

8. Remove the drive roller [B].
9. Replace the three separation belts [C] as a set.
NOTE: When setting the tension spring [D], set it on the hook [E]
normally. The hook [F] applies higher separation pressure.
Confirm that the separation belt is correctly set between the
guides [G].
Confirm that the snap rings [H] do not touch the separation belts.

A095/A096/A097 5-112 FSM

8.3 DUPLEX UNIT REMOVAL
[C] [A]

[B]

[C]

1. Open the front doors and remove the left door.

2. Remove the right inner cover [A]. (Refer to the right inner cover removal.)
3. Draw out the duplex unit [B] until the stop position.

Replacement &
Adjustment
4. Take out the right and left stopper pulleys [C] (1 snap ring each).
5. Take out the duplex unit.

FSM 5-113 A095/A096/A097

Rev. 12/93
8.4 SEPARATION CLUTCH/TRANSPORT CLUTCH REMOVAL

[E]

[B]
[D]
[A]
[C]

[B]
[G]

[F]
[A]

Before replacing both clutches, take out the duplex unit. (Refer to Duplex
Unit Removal.)
NOTE: When installing both clutches, be sure to set the stopper [A] to the
projection [B].

- Separation Clutch -
1. Remove the harness bracket [C] (1screw).
2. Remove the E-ring [D].
3. Replace the separation clutch [E].

- Transport Clutch -
1. Remove the E-ring [F].
2. Replace the separation clutch [G].

A095/A096/A097 5-114 FSM

8.5 JOGGER MOTOR REPLACEMENT
[C]

[D]

[B]

[G] [E]
[A]

Replacement &
[F]

Adjustment
1. Take out the duplex unit. (Refer to the duplex unit removal.)
2. Remove the duplex front cover (3 screws).
3. Slide the lever [A] to the rear then open the separation belt unit [B].
4. Remove the lower separation guide plate [C] (2 screws).
5. Remove the pressure arm [D] (1 snap-ring).
6. Remove the harness cover [E] (1 screw).
7. Remove the two connectors [F].
8. Remove the upper stay [G] (4 screws, 1 connector).

FSM 5-115 A095/A096/A097

Rev. 12/93

[D]

[C]

[A]

[G]
[B] [F]
[E]

[G]

9. Remove the positioning roller drive gear [A] (1 E-ring).

10. Remove the bushing [B] (1 E-ring).
11. Remove the positioning roller assembly [C].
12. Remove the front jogger fence [D] and the rear jogger fence [E] (1 screw
each).
13. Remove the duplex tray [F] (3 screws and a connector).
NOTE: To release the hooks [G], slide the duplex tray to the upper left
as shown.

A095/A096/A097 5-116 FSM

[A]
[C]
[B]

[A] [H]

[F]
[G]

[I]

Replacement &
Adjustment
[D]
[J] [H]
[E]
14. Remove the drive wire stoppers [A].
15. Unhook the tension spring [B] and remove the drive wire [C].
16. Remove the E-ring [D] and slide the shaft [E] to the left.
17. Remove the jogger motor bracket [F] (1 screw).
18. Remove the pressure arm solenoid [G] (1 screw).
19. Replace the jogger motor [H] (2 screws).
NOTE: When installing the drive pulley [I] to the jogger motor shaft, align
the shaft head [J] with the pulley head [H].
20. Re-assemble the duplex unit.

FSM 5-117 A095/A096/A097

Rev. 12/93
[A]
[D]
[B]

[G]

[C]
[F]

[I]
[H]

- Jogger Drive Wire Installation - [E]

1) Set the bead [A] which is closer to the red colored hook [B] in the hole
[C] and install the stopper [D] (1 screw).
2) Round the drive wire twice around the drive motor pulley [E] as shown.
3) Move the rear jogger fence bracket [F] to the rear end position (until
the bracket [F] touches the screw [G]) and keep this condition.
4) Under the above condition, place the front jogger fence bracket [H] to
the front end position (until the bracket [H] touches the front screw).
5) Install the stopper [I] to fix the front jogger fence bracket with the wire.

A095/A096/A097 5-118 FSM

[B]
[C]

[A]
[D]

[F]

[E]

Replacement &
NOTE: 1) When installing the jogger fences, confirm if the two positioning

Adjustment
pins [A] are correctly set in the two holes on the side fences after
the screw is set.
2) When installing the positioning roller assembly, insert the plate [B]
in the hole [C] on the rear frame, then set the plate on the lever
[D].
3) When installing the rear paper press mylar, set the hook [E] to the
rear jogger fence [F] as shown so that the mylar moves together
with the jogger fence [F].
4) After installing the jogger fences, manually move the jogger
fences [F] to confirm that they move smoothly.
5) After re-assembling the duplex unit, manually pull the plungers of
the positioning roller solenoid and the pressure arm solenoid to
confirm that the positioning roller assembly and the pressure arm
move up and down correctly.
6) After re-assembling the duplex unit, adjust the jogger fence width
so that the distance between both side fences become 1mm
wider than the paper size, when paper is set on the duplex tray.
( 1 SP adjustment mode – PAGE 10.)

FSM 5-119 A095/A096/A097

Rev. 12/93
9. COPY QUALITY ADJUSTMENT
9.1 SP Adjustment Mode
The copy quality adjustments in the table below can be performed by using
the appropriate 1 SP Adjustment mode.

SP Adjustment Change
Item Standard Default
– PAGE Amount/1 step
Leading edge
3 0 ± 2 mm 0.5 mm 00
registration
Leading edge
3 3.5 ± 2.5 mm 0.5 mm 00
erase margin
Vertical
3 100 ± 1% 0.1% 00
magnification
Horizontal
3 100 ± 1% 0.1% 00
magnification
Side to side
4 0 ± 2 mm 0.1% 00
registration
Focus in full size 5 — 0.1% 00
Focus in enlarge/
reduce (Lens 5 — 0.1% 00
error correction)

NOTE: When performing multiple adjustments, perform the items in order

from top to bottom.
Perform each adjustment as explained in the next pages.

A095/A096/A097 5-120 FSM

Rev. 12/93
[A] [B]

[C]

[E] [F]

[D]

Replacement &
1. Enter SP mode (refer to Service Program Access Procedure) and access

Adjustment
1 SP Adjustment mode.

2. Access the appropriate page by touching the "Prev." [A] or "Next" [B] key.
3. Touch the "Copy in SP" key [C] then select the proper copy mode.
4. Make a copy of the OS-A3 chart.
5. Confirm if copy quality is within the adjustment standard.
6. If the copy quality is not correct, touch the "SP Mode" key [D] at the left
upper corner of the LCD panel.
7. Touch the – key [E] or the + key [F] to change the data, then repeat
steps 3 to 6 until the copy quality becomes within the adjustment
standard.
8. Exit the SP mode.

FSM 5-121 A095/A096/A097

Rev. 12/93
9.2 SIDE-TO-SIDE REGISTRATION ADJUSTMENT

[D]
[A]

[C]

[B]

[F]
[E]
– Rough Adjustment –
1. Loosen the screws [A] for the tandem tray or built-in LCT, [B] for 550
sheets fixed tray or universal tray, or [C] for by-pass feed tray.
2. Move the tray position by moving parts [D], [E] and [F] of the trays.

– Fine Adjustment –
1. Enter SP mode (refer to the service program access procedure) and
access the side to side registration adjustment mode ( 1 SP
Adjustment – PAGE 4).

2. Adjust side-to-side registration for each feed station by changing the SP

mode data.
NOTE: Copies can be made in SP mode. Touch "Copy in SP" key to
select the paper feed station.
Adjustment standard: Less than ± 2 mm difference between
original and copy.

A095/A096/A097 5-122 FSM

Rev. 7/94
9.2.1 9.2.1 Side-to-side Registration Adjustment (A097 copier with RDH
and Finisher)
If the side-to-side image registration for paper fed from the duplex tray
should be adjusted, follow the entire procedure below.
If the side-to-side registration for duplex tray feed does not need to be
adjusted but side-to-side registration for the paper feed trays is necessary,
follow only steps 4 and 5 of the procedure below.

[D]

[A]

[C]

[B]

[E]

Replacement &
[F]

Adjustment
1. Enter SP mode (refer to the service program access procedure) and
access the side to side registration adjustment mode (SP Adjustment -
PAGE4).
2. Adjust side-to-side registration for the duplex tray by changing the SP
mode data.
NOTE: Copies can be made in SP mode. Touch "Copy in SP" key to
select the paper feed station.

Adjustment standard: Less than ±2mm difference between

original and copy.
3. Change the SP data of each paper feed tray so that it is the same as the
SP data of the duplex tray.
4. Loosen the screws [A] for the tandem tray or built-in LCT, [B] for
universal tray, or [C] for by-pass feed tray
5. Reposition the tray by moving parts [D], [E] and [F] of the trays.

FSM 5-122 A A095/A096/A097

Rev. 7/94

This page intentionally left blank

A095/A096/A097 5-122 B FSM

Rev. 12/93
9.3 UNEVEN EXPOSURE ADJUSTMENT
When: If the exposure is uneven.
Purpose: To maintain even exposure.
Adjustment standard: The side-to-side variation of the gray scales on
the test chart should be less than one level.
How: Change the position of the exposure lamp or
exposure adjustment wings to make light
intensity from the exposure lamp even across its
length.

Replacement &
Adjustment
[A]

Wing positioning:

Image turns darker.

Image turns lighter.

1. Remove the exposure glass. (See Exposure Glass Removal.)
2. Position the adjustment wings [A] so that the side-to-side copy image
density variation is within the adjustment standard.
3. Turn on the main switch and enter SP mode, then perform the process
control data initial setting ( 1 SP Adjustment – PAGE 1).
NOTE: If uneven density is not solved by this adjustment, proceed to the
steps 4 and 5 in the next page.

FSM 5-123 A095/A096/A097

[B]

[B]

[C]

[C]

[A]

[D]
[A]

4. Turn the screw [A] to correct the position of the filament. The left edge of
the exposure lamp [B] should be directly beneath the center of the sight
hole [C] in the reflector cover.

CAUTION: Do not touch the screw [D].

5. Turn on the main switch and enter SP mode, then perform the process
control data initial setting ( 1 SP Adjustment – PAGE 1).

A095/A096/A097 5-124 FSM

Rev. 12/93
9.4 IMAGE DENSITY ADJUSTMENT
When: The copy image density is already adjusted to the standard level
at the factory, and process control maintains copy image density
until the next PM. If the customer asks you to adjust the image
density, it can be done by using the User Tool mode.
Purpose: To adjust the copy image density.
How: The User Tool "image density level" mode changes the
development bias voltage.
1. Enter User Tool mode and access 5 Set operation modes.

2. Press the Next key once.

3. Select the appropriate image density

level (5 steps). [C]

adjustment:
[B]
1) Press the appropriate ID level [A]
key [A].
2) Press the enter key [B].

4. Press the "Menu" key [C].

Replacement &
Adjustment
5. Press the "Exit" key [D] to exit
[D]
User Tool mode.

6. Check copy quality.

FSM 5-125 A095/A096/A097

Rev. 12/93
9.5 SCANNER HEIGHT ADJUSTMENT
When: If optically skewed images appear after
adjusting the 1st and 2nd scanner positions.
Purpose: To maintain a proper copy image.
How: Turn the 3rd scanner height adjusting cam.
This changes the 3rd scanner’s height.

[A]

[B]

1. Remove the upper right cover [A]. (Refer to the upper right cover
removal.)
2. Remove the lens unit cover [B].
3. Move the third scanner to the far right position.

A095/A096/A097 5-126 FSM

[A]

[B]

4. Peel off the cover seal [A].

5. Loosen the Allen screw on the adjusting cam [B].
6. Adjust the third scanner height by turning the adjusting cam. (This is a
fine adjustment.)

Replacement &
Adjustment

FSM 5-127 A095/A096/A097

[A]

[B]
[C]
[C]

[D]

7. If a fine adjustment is insufficient, make a rough adjustment then make

the fine adjustment again.

- Rough adjustment -
1) Remove the air inlet duct [A](1 screw).
2) Peel off the cover seal [B].
3) Loosen the screws [C].
4) Rotate the rough adjustment cam [D], as shown, to adjust the third
scanner height.
Black arrow ---- Raise the rear side
White arrow ---- Lower the rear side
NOTE: Normally the cut out of the adjustment cam is at nine o’clock.
5) Tighten the screw [C] after the adjustment.

A095/A096/A097 5-128 FSM

Rev. 7/94
10. TOUCH PANEL DISPLAY ADJUSTMENT

Adjust the Touch Panel display position as follows:

1. Press the Interrupt key then press and hold the Clear/Stop key for more
than three (3) seconds.
2. Follow the guidance on the LCD.
C
3. Touch the upper left corner [A].
4. Touch the lower right corner [B].

[B]

[A]

Replacement &
Adjustment
5. When touching the corners, use a small object such as a pen or pencil
point but DO NOT press too hard to avoid damage to the Touch Panel.
6. Touch a few positions to confirm whether the touch panel is correctly
adjusted.
7. When a portion of the Touch Panel is touched, the corresponding
position indicates a "+" mark. If this "+" mark is more than 7mm away
from the precise point touched, press the Clear/Stop key and start the
adjustment procedure from the beginning.
8. If the adjustment is correct, press the Enter key to save the adjustment
position to memory.

NOTE: DO NOT skip step 8 of this procedure, otherwise, the result of

the latest adjustment is ignored.

FSM 5-129 A095/A096/A097

Rev. 6/13/97

11. SERVICE TIPS

Block Diagram of the Latent Image Control System

If VD or VL are not within specification

• Check service code counters: Enter SP mode, select item 6. Check service
code counters, this may indicate a component failure.

Confirm exposure lamp voltage

• Turn process control off: Enter SP Adjustments, page 7, item 4. Select
reset. (Refer to FSM page 4-12).
• Adjust exposure lamp voltage: Adjust Exposure Lamp voltage to 55 VAC.
SP mode Adjustment page 9, item 1. (Refer to FSM page 4-13).
• Confirm the exposure lamp voltage: Connect RMS. meter to CN704 pins 1
and 2 on the AC Drive Board. Make a copy, the output voltage should be
approximately 55 ±.5 VAC. This will vary slightly from machine to machine, due
to variations in the machines and wall voltage.

If Exposure Lamp AC voltage is out of range

• Confirm the Exposure Lamp PWM voltage: at TP519 on the Optics Control
Board (refer to the chart below).If Exposure Lamp PWM voltage is out of range,
try replacing the Optics Control Board. If Exposure Lamp PWM voltage is in
range, try replacing the AC drive Board.
• Check the Lamp Monitor Signal: at TP106 on the Main Board. since the
Lamp Monitor Signal can vary from machine to machine, use the chart below as
a reference, not a specification.

Voltage levels from several working machines were averaged for this chart.

FSM 5-130 A095/A096/A097

Rev. 6/13/97

Block diagram of Exposure Lamp circuit

Exposure Lamp voltage data is sent to the Optics Control Board by the Main Board
(TXD). In turn, the Optics Control Board sends the Exposure Lamp PWM to the
AC Drive Board. The main CPU monitors the Lamp Monitor Signal and makes
changes to the data (TXD) to compensate for minor fluctuations in line voltage.

Block diagram of the Lamp Monitor circuit located on the AC drive Board.

The purpose of the lamp monitor circuit is to monitor the AC line voltage and
to compensate for minor fluctuations in the line voltage.
Confirm Charge and Grid PWM
1. Turn off Process Control, SP Adjustment page 8, select reset.
2. Adjust Grid Voltage to 870 volts,(see chart below) to confirm Grid and Charge
PWM.
3. Connect meter CN602 on High Voltage Control Board (see chart below).
4. Make a copy with meter connected, to monitor Charge and Grid PWM.

The 700 to 1200 volt range is provided to illustrate the relationship between Charge and Grid PWM

Confirm Development Bias

1. View development bias, SP mode Data Out, page 2, “Development Bias,
Image”.
2. Enter Output mode, SP Test Mode, page 3. Enter output number 62.
3. Connect meter to Development unit magnetic roller front pin and frame ground.
4. Compare the readings from data out and voltage from meter reading. If vastly
different, check the Development Bias Terminal for over greasing (grease is
conductive and can provide development bias voltage a path to ground). If the
Development Bias Terminal is OK, try replacing the High Voltage Control
Board.

A095/A096/A097 5-131 FSM

Rev. 6/13/97

Inspect the VL patch

Ensure the VL patch, under the left scale has not darkened from age and/or
exposure to heat and light.

Confirm the Small VL patch, (located under the left optics frame on the VD patch)
is positioned properly and has not darkened. Refer to FT6645/55/65 TSB -
22 for positioning information.
First
Left Scale S

Scanner home position.

VL Patch Position where VD is
under left scale. checked.
A Position where VL is
B checked.
Approx. 50mm.

Confirm first scanner position in relation to VD and VL patch.

1. With the first scanner at home position, make a pencil mark on the top cover
corresponding with point “A” above.
2. Perform Process Control. (SP Adjustment page 1, item 2)
3. Observe the first scanner movement. When it moves to the point corresponding
to point “B” above, make a second pencil mark.
4. Remove the exposure glass, then reinstall the left scale.
5. Move the first scanner to pencil mark “B”. Look into optics assembly, in the
upper portion of the third mirror. The VL patch or Small VL patch should be
visible.
6. Move the first scanner to pencil mark “A”. Look into third mirror. The VD patch
should be visible
7. If either patch is not visible, the first scanner position is not correct.

Possible causes
1. Improper scanner wire tension.
2. Mechanical bind in scanner.
3. Scanner home position sensor bracket and/or scanner home position actuator
incorrect.

If all checks are confirmed and copies are still light, replace the Exposure Lamp.

FSM 5-132 A095/A096/A097

Rev. 6/13/97

If VM100/VM800 do not fall within Specifications.

5HDU 7KH'UXP
'HYHORSPHQ *URXQGLQJ
W8QLW 3ODWH
+ROGHU FRQQHFWRU

7KH+LJK
9ROWDJH
FRQWURO 7KH'UXP
%RDUG. *URXQGLQJ
3ODWH
$
1. Enter SP mode
2. Enter SP Test Mode page 3.
3. Select Output mode.
4. Enter output number 57 (VM100)
5. Connect your (+) meter lead to the Drum Grounding Plate connector(see above).
6. Connect your (-) meter lead to frame ground.
7. Press “ON” on the touch screen to turn on VM100.
8. Monitor the voltage on you meter.
9. Enter output number 58 (VM800)
10. Press “ON” on the touch screen to turn on VM800.
11. Monitor your meter.

• If both voltages are in specification, the voltages applied during potential sensor
calibration are good.
• If either voltage is out of specification, disconnect CN604 and check the
voltages again (see above).

• During potential sensor calibration, the same voltages are applied to the
development unit and drum shaft to prevent toner from being transferred to the
drum. If there is an electrical short or resistance to the frame in the development
unit or Rear Development Unit Holder it may effect the VM100/800 voltage. Also
missing OPC material (chips) in the surface of the drum may cause VM800 to
arc through the drum, resulting in improper VM800 voltage.

If voltages are still out of specification:

• Replace the High Voltage Control Board.
If voltages are good:
• Inspect the Drum Grounding Plate and Drum Drive Shaft for wear.
• Inspect the drum grounding tab located inside the OPC drum, for toner
contamination and good contact.
• Try replacing the drum potential sensor (AW330003)

A095/A096/A097 5-133 FSM

Rev. 6/13/97

General Notes:
VL
If VL data is too high, process control sees the VL patch as too dark
Possible causes:
• Scanner home position incorrect or mechanical problem with scanner
• VL patch has become darker with age, light and heat
• Small VL patch is not installed or not positioned properly. First scanner
overruns home position and sees the VD patch instead of VL patch. This raises
the Exposure Lamp voltage, this causes light copies (see A095/A096 TSB-22).
• Improper voltage supplied to the Exposure Lamp. (AC Drive Board/Optics
Control Board)
• Dirty optics.
• Bad Exposure Lamp (too dim).
If VL data is too low, process control sees the VL patch as too light.
Possible causes:
• Improper voltage supplied to the Exposure Lamp. (AC Drive Board/Optics
Control Board)
• Bad Exposure Lamp (too bright).
• Insufficient charge on the OPC drum
VD
If VD data is too high, process control sees the VD patch as too dark.
Possible causes:
• Excessive charge on the OPC drum
• Dirty optics
• See “If VL data is too high”
If VD data is too low, process control sees the VD patch as too light.
Possible causes:
• Same as “if VL data is too low”
VR

If VR is too high, excessive residual voltage on the OPC drum.

Possible causes:
• Poor drum ground.
• Replace the OPC drum.
NOTE: If VD and VL are in specification and abnormal copy quality continues, it may be
necessary to perform the RAM clear procedure to obtain new data (since process control
reverts to previous data, if VD or VL falls out of specification). If new data is in
specification, the problem is not in latent image control. If new data is out of specification
or if new data is not obtained (after a RAM clear) the problem is in latent image
control.

FSM 5-134 A095/A096/A097

Rev. 6/13/97

A095/A096/A097 - Service Tips: Paper Feed/Paper Lift

Figure 1.
Clean/Inspect
Figure 2. Figure 4.
Separation
Area where Feed Roller
Solenoid &
separation Lever. one way
Linkage roller can bearing
disengage. (A0966353)

Figure 3.
Install washer
(017010060)

Figure 6. Figure 7.
Figure 5. Clean the Feed Clutch Clean/Inspect pick
Inspect the lift surfaces with up solenoid &
motor for damaged Scotchbrite™ and alcohol, linkage
gears if surfaces appear
oxidized.
• Binding Separation Solenoid and/or Linkage: Figure 1. If the separation solenoid
and/or linkage become mechanically bound, separation problems can result. Inspect
this assembly for proper operation. Clean/inspect as needed.
• Disengaging Separation Roller/Torque Limiter Clutch: Figure 2. If excessive end
play develops, separation problems will result. Install the Washer (017010060) as
shown in Figure 3 to eliminate end play. Replace the Torque Limiter clutch as needed.
• Failure of the Feed Roller Lever: Figure 4. Failure of the Feed Roller Lever
(A0966353) can result in “Z-folding” at the Registration Roller, paper feed jamming and
copy paper being “kicked back” into the feed tray during paper feed. When replacing
the Feed Roller Lever, inspect the Feed Roller Shaft (AA140498). If it appears polished
use Scotchbrite™ to remove the glazed surface or replace the shaft.
• Lift motor gear breakage: Figure 5. When the lift motor gears become damaged,
SC502, 503 and 504 can result. A severe bind can cause IC 407 and/or 408
(located on the Paper Feed Board) to become damaged. We believe that these gears
have been changed to a more durable material.
• Paper Feed Clutch: Figure 6. Inspect, clean or replace as necessary (see above).
• Pick-up Solenoid and /or Linkage binding: Figure 7. If there is a mechanical bind
in the Pick Up Solenoid assembly, it will result in paper feed problems and/or paper lift
problems. Clean/inspect as necessary. In order for the paper tray bottom plate to lift,
the pick up solenoid must energize first; this positions the lift sensor flag into the lift
sensor.
A095/A096/A097 5-135 FSM
Rev. 6/13/97

A095/A096/A097 - Service Tips: Transfer Unit

Figure 1.
Ensure that parts Figure 2.
A, B & C are If Transfer lift
cleaned every PM problems occur,
install updated
parts.

Figure 3.
Inspect Transfer Figure 4.
Belt for pin holes. If breakage or
bending occurs,
install updated
parts.

• To avoid erratic operation caused by electrical noise (arcing): Figure

1. Item A, the Transfer Bias Roller (A0963870) should be Inspected and
cleaned at every PM Scotchbright or replace as needed. Figure 1. Item
B, the Transfer Belt Terminal (A0963864) follow the same procedure as
item A. Figure 1. Item C, The Rear Spring Plate (A0963860), follow the
same procedure as items A & B. File surface smooth or replace as needed.

• If problems occur with the Transfer Lift Solenoid: Figure 2. Install

updated parts. (For details refer to TSB FT6645/55/65 - 46)
A. The Transfer Belt Solenoid (A0963921).
B. The Solenoid Bracket (A0963922).
C. The Transfer Belt Casing (A0963924)

• If erratic operation occurs: Figure 3. Closely inspect the surface of the

Transfer Belt (A0963652), for pin holes. If pin holes are visible, replace the
Transfer Belt.

• If damage or breakage occurs to the Release Arm or the Belt Unit

Knob:
Figure 4. Install updated parts.
A. Release Arm (A0963959) new part number.
B. Belt Unit Knob (A0963960) new part number.

FSM 5-136 A095/A096/A097

Rev. 6/13/97

A095/A096/A097 - Service Tips: Fusing Unit

Figure 5.
A097 confirm the
AC Drive Board
part number silk
screened on the board

Figure 1.
Thermistor
placement in
relation to heat
curve.

Figure 4.
Figure 3. Figure 2.
A097
Flat spot in the Install Thermistor
Inspect Bushings
Pressure Roller Film (A0964209)
may occur on machines (AA082603) at PM interval.
Not available as an assembly on A096 Ensure silicone oil is applied
that sit idle for extended
periods of time
• FYI: We have received several Technical Alerts that suggested repositioning the
Thermistor away from the center of the Hot Roller (to avoid toner build up on the Thermistor).
The Thermistor must be placed near the center of the Hot Roller. This is due to the actual
temperature characteristics of the Hot Roller. The Thermistor must monitor the Hot Roller at
its hottest point (see Figure 1. above). This design avoids temperature overshoot or
undershoot common with other fuser designs. (7000 series “Please wait warming up” during
long copy runs) Repositioning the Thermistor violates UL standards. Any fusing unit
modified in this way, must be restored to manufacturers standards immediately

• To avoid toner build up on the Thermistor: Figure 2. Install the Thermistor Film
(A0964209) and apply a thin film of silicone oil. At every EM call inspect /clean or replace the
Thermistor Film.

• Pressure Roller flat spot: Figure 3. If a pressure roller flat spot occurs, enter SP
Adjustments page 1. And select the 10 minute fusing idling period. This should eliminate
the flat spot. This may occur on low use machines.

• A097: Figure 4. FT6665 please inspect the bushings in the pressure roller cleaning roller
assembly at the PM interval for wear. Replace as necessary. This is not available as an
assembly, parts must be ordered individually. Preliminary information from RCL indicates
that this assembly will be improved.

• Figure 5. When experiencing temperature related problems on an FT6665, confirm that the
part number silk screened on the AC Drive Board has a A097 prefix see TSB 6645/55/65 -
54 Update 6

A095/A096/A097 5-137 FSM

Rev. 6/13/97

A095/A096/A097 - Service Tips: Duplex feed

Figure 6. Figure 5.
Separation Jogger Span Figure 4.
Clutch Adjustment Lever Exit Guide
(AX200092) SP adj. (A0964891)
Pg. 11
Figure 7.
Gear
(AB010089

)LJXUH
2QH :D\
%XVKLQJ
$$
;;PP )LJXUH
2QH :D\ Figure 3.
%XVKLQJ One Way Gear
$$ (AB013802) 35Z
;;PP

• One way bushings and bearings: Figures 1, 2 and 3 are the 3 one way
bushings\bearings that are located in the duplex feed system. All can cause
problems feeding out of Duplex.

• Lever exit guide: Figure 4. Can become warped, causing jams in the Duplex
exit area. Reform or replace as necessary.

• Jogger Span Adjustment: Figure 5. Is the most common cause of Duplex

feed out jams. Feed a sheet of paper into the duplex unit. Pull out Duplex Unit.
Confirm that the Jogger Fences are 1mm wider than the paper in the Duplex
Tray. Confirm this for each paper size

• Duplex Separation Clutch: Figure 6. Duplex separation Clutch may be slippin

binding. Clean or replace as necessary.

• Separation drive gear: Figure 7. We have seen one case of this gear
developing a (difficult to see) hairline crack. The gear would separate during a
long run, resulting in an intermittent Duplex feed out jam.

FSM 5-138 A095/A096/A097

Rev. 6/13/97

$$$6HUYLFH7LSV2SWLFV$VVHPEO\

Figure 2.
After replacing the
Figure 1.
Scanner Drive
Exposure
Wires, be sure to
Lamp
perform optics free
Harness
run. Then perform
(A0965477)
the Scanner Control
Adjustment.

Figure 4.
The Scanner
Motor(AX070008)
Figure 3.
If the Horizontal Lens
Drive Motor vibrates,
check here (see below).

• Figure 1. If excessive wear or breakage occurs to the Exposure Lamp

Harness, refer to TSB’s FT6645/55/65 - 13, 21 update no. 2 and 54 update
no. 3
• Figure 2. After replacing the Scanner drive wires, be sure to follow
the procedures on FSM page 5-31 and 32. Failure to do so may result in
jams at the registration sensor.
• Figure 3. If the Horizontal or vertical lens drive motors vibrate and generate
a lens drive SC code, carefully inspect the solder joints and connectors on the
harnesses that supply the stepper motors. When the lens stepper motors are not
rotating, 24 volts should be available at all the pins supplying the motor.
• Figure 4. Scanner motor failure can cause SC 125, erratic operation and
registration jams.
• If the Scanner Drive Wires come off during operation: Refer to, TSB’s
FT6645/55/65 - 7R, 31R, 39 update 3. also refer to “Common Transfer Unit
Problems” and “Common Drum and Development Unit Problems”
NOTE:
Registration jams can occur due to a problem in the optics
1. Binding in the scanner.
2. Incorrect drive wire tension.
3. Electrical noise generated by the scanner drive motor.
4. Improperly set scanner control adjustment.
These can all cause registration jamming. Reason: Registration timing is
based on optics timing, if the optics is functioning at the incorrect speed,
registration timing will be incorrect, resulting in a jam.

A095/A096/A097 5-139 FSM

Rev. 6/13/97

A095/A096/A097 - Service Tips: Drum and Development units.

Figure 2.
Cleaning Blade
flips. Perform
procedure listed
below.

Figure 1.
Install wire jumper Figure 4.
across front pins Clean & Inspect
of Development Drum ground tab.
rollers.

Figure 3.
Inspect Cleaning Figure 5.
Brush ground. Erratic erase
lamp operation.
(See below

• Figure 1. Developer bias is applied to the lower rear Development roller. The
rear Development roller holder is composed of a conductive resin, which allows
the bias to reach the upper Development roller. Measure the bias at each pin on
the front of the Development unit. Use Output Test Mode #62. If the bias is not
the same on each pin, install a jumper across these two pins to allow bias to be
applied to both rollers.
• Figure 2. After replacing the Cleaning Blade, prime both the Drum and Cleaning
Blade with setting powder. With the upper half of the drum unit open, rotate the
Drum in a counterclockwise direction to allow a bead of setting powder to form
across the Cleaning Blade. Then turn the Drum in a clockwise direction to
insure smooth movement between the Drum and Cleaning Blade.
• Figure 3Clean and inspect the cleaning brush ground. Having a poor ground
contact at this point can result in erratic electrical problems stated in the
following TSB’s: FT6645/55/65 - 7R, 31R and 39 update 3.
• Figure 4. If poor Drum ground is suspected, Clean, inspect and adjust the
Drum ground tab just inside the Front section of the Drum.
• Figure 5. If Erratic Erase Lamp operation occurs, perform the items mentioned
in TSB’s FT6645/55/65 - 7R, 31R. Replace the erase lamp unit if these do not
correct the problem. Note: If Erase lamp pattern is burned into the Drum or
appears on copies, perform the ROM update stated in TSB FT6645/55/65 -
034.

FSM 5-140 A095/A096/A097

Rev. 6/13/97

LATENT IMAGE CONTROL SLIDE RULE DATA REV. 6/13/97

VR VD VD VD VL VL VL DV VR VD VD VD VL VL VL DV
LOW HIGH LOW HIGH BIAS LOW HIGH LOW HIGH BIAS
1 771 751 791 141 121 161 221 102 872 852 892 242 222 262 322
2 772 752 792 142 122 162 222 103 873 853 893 243 223 263 323
3 773 753 793 143 123 163 223 104 874 854 894 244 224 264 324
4 774 754 794 144 124 164 224 105 875 855 895 245 225 265 325
5 775 755 795 145 125 165 225 106 876 856 896 246 226 266 326
6 776 756 796 146 126 166 226 107 877 857 897 247 227 267 327
7 777 757 797 147 127 167 227 108 878 858 898 248 228 268 328
8 778 758 798 148 128 168 228 109 879 859 899 249 229 269 329
9 779 759 799 149 129 169 229 110 880 860 900 250 230 270 330
10 780 760 800 150 130 170 230 111 881 861 901 251 231 271 331
11 781 761 801 151 131 171 231 112 882 862 902 252 232 272 332
12 782 762 802 152 132 172 232 113 883 863 903 253 233 273 333
13 783 763 803 153 133 173 233 114 884 864 904 254 234 274 334
14 784 764 804 154 134 174 234 115 885 865 905 255 235 275 335
15 785 765 805 155 135 175 235 116 886 866 906 256 236 276 336
16 786 766 806 156 136 176 236 117 887 867 907 257 237 277 337
17 787 767 807 157 137 177 237 118 888 868 908 258 238 278 338
18 788 768 808 158 138 178 238 119 889 869 909 259 239 279 339
19 789 769 809 159 139 179 239 120 890 870 910 260 240 280 340
20 790 770 810 160 140 180 240 121 891 871 911 261 241 281 341
21 791 771 811 161 141 181 241 122 892 872 912 262 242 282 342
22 792 772 812 162 142 182 242 123 893 873 913 263 243 283 343
23 793 773 813 163 143 183 243 124 894 874 914 264 244 284 344
24 794 774 814 164 144 184 244 125 895 875 915 265 245 285 345
25 795 775 815 165 145 185 245 126 896 876 916 266 246 286 346
26 796 776 816 166 146 186 246 127 897 877 917 267 247 287 347
27 797 777 817 167 147 187 247 128 898 878 918 268 248 288 348
28 798 778 818 168 148 188 248 129 899 879 919 269 249 289 349
29 799 779 819 169 149 189 249 130 900 880 920 270 250 290 350
30 800 780 820 170 150 190 250 131 901 881 921 271 251 291 351
31 801 781 821 171 151 191 251 132 902 882 922 272 252 292 352
32 802 782 822 172 152 192 252 133 903 883 923 273 253 293 353
33 803 783 823 173 153 193 253 134 904 884 924 274 254 294 354
34 804 784 824 174 154 194 254 135 905 885 925 275 255 295 355
35 805 785 825 175 155 195 255 136 906 886 926 276 256 296 356
36 806 786 826 176 156 196 256 137 907 887 927 277 257 297 357
37 807 787 827 177 157 197 257 138 908 888 928 278 258 298 358
38 808 788 828 178 158 198 258 139 909 889 929 279 259 299 359
39 809 789 829 179 159 199 259 140 910 890 930 280 260 300 360
40 810 790 830 180 160 200 260 141 911 891 931 281 261 301 361
41 811 791 831 181 161 201 261 142 912 892 932 282 262 302 362
42 812 792 832 182 162 202 262 143 913 893 933 283 263 303 363
43 813 793 833 183 163 203 263 144 914 894 934 284 264 304 364
44 814 794 834 184 164 204 264 145 915 895 935 285 265 305 365
45 815 795 835 185 165 205 265 146 916 896 936 286 266 306 366
46 816 796 836 186 166 206 266 147 917 897 937 287 267 307 367
47 817 797 837 187 167 207 267 148 918 898 938 288 268 308 368
48 818 798 838 188 168 208 268 149 919 899 939 289 269 309 369
49 819 799 839 189 169 209 269 150 920 900 940 290 270 310 370
50 820 800 840 190 170 210 270 151 921 901 941 291 271 311 371
51 821 801 841 191 171 211 271 152 922 902 942 292 272 312 372
52 822 802 842 192 172 212 272 153 923 903 943 293 273 313 373
53 823 803 843 193 173 213 273 154 924 904 944 294 274 314 374

A095/A096/A097 5-141 FSM

Rev. 6/13/97

54 824 804 844 194 174 214 274 155 925 905 945 295 275 315 375
55 825 805 845 195 175 215 275 156 926 906 946 296 276 316 376
56 826 806 846 196 176 216 276 157 927 907 947 297 277 317 377
57 827 807 847 197 177 217 277 158 928 908 948 298 278 318 378
58 828 808 848 198 178 218 278 159 929 909 949 299 279 319 379
59 829 809 849 199 179 219 279 160 930 910 950 300 280 320 380
60 830 810 850 200 180 220 280 161 931 911 951 301 281 321 381
61 831 811 851 201 181 221 281 162 932 912 952 302 282 322 382
62 832 812 852 202 182 222 282 163 933 913 953 303 283 323 383
63 833 813 853 203 183 223 283 164 934 914 954 304 284 324 384
64 834 814 854 204 184 224 284 165 935 915 955 305 285 325 385
65 835 815 855 205 185 225 285 166 936 916 956 306 286 326 386
66 836 816 856 206 186 226 286 167 937 917 957 307 287 327 387
67 837 817 857 207 187 227 287 168 938 918 958 308 288 328 388
68 838 818 858 208 188 228 288 169 939 919 959 309 289 329 389
69 839 819 859 209 189 229 289 170 940 920 960 310 290 330 390
70 840 820 860 210 190 230 290 171 941 921 961 311 291 331 391
71 841 821 861 211 191 231 291 172 942 922 962 312 292 332 392
72 842 822 862 212 192 232 292 173 943 923 963 313 293 333 393
73 843 823 863 213 193 233 293 174 944 924 964 314 294 334 394
74 844 824 864 214 194 234 294 175 945 925 965 315 295 335 395
75 845 825 865 215 195 235 295 176 946 926 966 316 296 336 396
76 846 826 866 216 196 236 296 177 947 927 967 317 297 337 397
77 847 827 867 217 197 237 297 178 948 928 968 318 298 338 398
78 848 828 868 218 198 238 298 179 949 929 969 319 299 339 399
79 849 829 869 219 199 239 299 180 950 930 970 320 300 340 400
80 850 830 870 220 200 240 300 181 951 931 971 321 301 341 401
81 851 831 871 221 201 241 301 182 952 932 972 322 302 342 402
82 852 832 872 222 202 242 302 183 953 933 973 323 303 343 403
83 853 833 873 223 203 243 303 184 954 934 974 324 304 344 404
84 854 834 874 224 204 244 304 185 955 935 975 325 305 345 405
85 855 835 875 225 205 245 305 186 956 936 976 326 306 346 406
86 856 836 876 226 206 246 306 187 957 937 977 327 307 347 407
87 857 837 877 227 207 247 307 188 958 938 978 328 308 348 408
88 858 838 878 228 208 248 308 189 959 939 979 329 309 349 409
89 859 839 879 229 209 249 309 190 960 940 980 330 310 350 410
90 860 840 880 230 210 250 310 191 961 941 981 331 311 351 411
91 861 841 881 231 211 251 311 192 962 942 982 332 312 352 412
92 862 842 882 232 212 252 312 193 963 943 983 333 313 353 413
93 863 843 883 233 213 253 313 194 964 944 984 334 314 354 414
94 864 844 884 234 214 254 314 195 965 945 985 335 315 355 415
95 865 845 885 235 215 255 315 196 966 946 986 336 316 356 416
96 866 846 886 236 216 256 316 196 966 946 986 336 316 356 416
97 86 847 887 237 217 257 317 196 966 946 986 336 316 356 416
98 86 848 888 238 218 258 318 197 967 947 987 337 317 357 417
99 86 849 889 239 219 259 319 198 968 948 988 338 318 358 418
100 870 850 890 240 220 260 320 199 969 949 989 339 319 359 419
101 871 851 891 241 221 261 321 200 970 950 990 340 320 360 420

FSM 5-142 A095/A096/A097

TROUBLESHOOTING
1. SERVICE CALL CONDITIONS
1.1 SUMMARY
There are 4 levels of service call conditions.

Level Definition Display

The SC can only be reset SC display will not be canceled.
by service representative
(see note in the next page)
to prevent the machine
from being damaged.
A The copier cannot be
operated at all.

The copier can be If the related function is selected, this

operated as usual except display appears.
for the unit related to the
service call.

shooting
Only the SC counter is SC will not be displayed. Trouble-
C incremented. The copier
can be operated as usual.
The SC can be reset by
turning main switch off and
on if the SC is caused by
misdetection.
D

FSM 6-1 A095/A096/A097

NOTE: 1) If the problem is related to electrical circuit boards, first
disconnect then reconnect the connectors before replacing the
PCBs.

2) If the problem is related to motor lock, first check the mechanical

load before replacing motors or sensors.

3) To reset the SC of "Level: A", enter SP mode then turn the main
switch off and on.

4) When an SC condition occurs while in SP mode, the display does

not indicate the SC number. You can recognize the SC condition
because in this condition, you cannot exit the SP mode by
touching the Quit key.
If this occurs, confirm the SC number as follows:
1. Perform the same procedure to duplicate the SC condition.
2. Enter "Copy in SP" mode. You can see the SC number on the
display. You can also confirm the SC number by checking the
increment of the SP mode SC counter ( 6 Jam/SC Counter
– PAGE 1).

A095/A096/A097 6-2 FSM

1.2 EXPOSURE
SC101 - Exposure lamp malfunction - abnormal On/Off
Definition: [level: A]
During the lamp off condition, the optics control board detects a lamp voltage.
Possible causes
• Exposure lamp open
• Triac shorted
• Exposure lamp thermoswitch open
• Optics control board defective

SC103 - Power source frequency detection error

Definition: [level: D]
Detects frequencies out of the 45Hz to 65Hz range.
Possible causes:
• Abnormal power source
• Electrical noise
• AC drive board defective
• Optics control board defective

SC104 - Exposure lamp malfunction - abnormal off

Definition: [level: D]
The scanner start signal is received even if the main relay off condition is
detected.
Possible causes:
• Main relay defective
• Communication error between the main control board and the optics
control board because of a poor harness connection.
• Optics control board defective

shooting
Trouble-
1.3 SCANNER
SC120 - Scanner home position sensor abnormal - stays off
Definition: [level: D]
The scanner home position sensor does not detect the on condition even if
the scanner returns home.
Possible causes:
• Scanner home position sensor defective
• Optics control board defective

FSM 6-3 A095/A096/A097

SC121 - Scanner home position sensor abnormal - stays on (Stays at 5V)
Definition: [level: D]
The scanner home position sensor does not detect the off condition (low)
even if the scanner leaves the scanner home position sensor by 120 mm.
Possible causes:
• Scanner home position sensor defective
• Scanner motor defective
• Scanner HP sensor short

SC125 - Low scanner speed

Definition: [level: D]
The scanner speed, detected by the optics control board through the
encoder, is lower than the specified speed.
Possible causes:
• Scanner drive motor defective
• Optics Control Board defective

SC126 - High scanner speed

Definition: [level: D]
The scanner speed, detected by the optics control board through the
encoder, is higher than the specified speed.
Possible causes:
• Scanner drive motor defective
• Optics control board defective

SC127 - Scanner drive motor encoder failure

Definition: [level: D]
Scanner rotating direction detected by the optics control board through the
encoder is opposite to the specified direction.
Possible causes:
• Scanner drive motor defective
• Optics control board defective

A095/A096/A097 6-4 FSM

1.4 LENS MAGNIFICATION
SC140 - Lens vertical home position sensor abnormal - stays off (Stays
OV).
Definition: [level: D]
When the lens returns to the home position, the lens vertical home position
sensor does not detect the on condition (5V) for 2 seconds or more, and
more than twice.
Possible causes:
• Lens vertical home position sensor shorted
• Lens vertical drive motor defective
• Optics control board defective

SC141 - Lens vertical home position sensor abnormal - stays on (Stays

5V).
Definition: [level: D]
When the lens returns to the home position, the lens vertical home position
sensor does not detect the off condition for 3.5 seconds or more, and more
than twice.
Possible causes:
• Lens vertical home position sensor open
• Lens vertical drive motor defective
• Optics control board defective

SC142 - Lens horizontal home position sensor abnormal - stays off

(Stays OV).
Definition: [level: D]
When the lens returns to the home position, the lens horizontal home position
sensor does not detect the on condition (5V) for 1.7 seconds or more, and

shooting
Trouble-
more than twice.
Possible causes:
• Lens horizontal home position sensor short
• Lens horizontal drive motor defective
• Optics control board defective

FSM 6-5 A095/A096/A097

SC143 - Lens horizontal home position sensor abnormal - stays on
(Stays 5V).
Definition: [level : D]
When the lens leaves from the home position, the lens horizontal home
position sensor does not detect the off condition (OV) for 2.3 seconds or
more, and more than twice.
Possible causes:
• Lens horizontal home position sensor open
• Lens horizontal drive motor defective
• Optics control board defective
SC144 - 3rd scanner home position sensor abnormal - stays off (Stays
OV).
Definition: [level: D]
When the 3rd scanner returns to the home position, the 3rd scanner home
position sensor does not detect the on condition (5V) for 1.2 seconds or
more, and more than twice.
Possible causes:
• 3rd scanner home position sensor shorted
• 3rd scanner drive motor defective
• Optics control board defective

SC145 - 3rd scanner home position sensor abnormal - stays on (Stays

5V).
Definition: [level: D]
When the 3rd scanner leaves from the home position the 3rd scanner home
position sensor does not detect the off condition (OV) for 2.0 seconds or
more, and more than twice.
Possible causes:
• 3rd scanner home position sensor open
• 3rd scanner drive motor defective
• Optics control board defective

SC146 - Abnormal magnification operation

Definition: [level: D]
The lens vertical drive motor or the lens horizontal drive motor move for no
apparent reason in the ready condition.
Possible causes:
• Lens vertical drive motor defective
• Lens horizontal drive motor defective
• 3rd scanner drive motor defective
• Optics control board defective

A095/A096/A097 6-6 FSM

1.5 OPTICS THERMISTOR
SC190 - Optics thermistor open
Definition: [level: D]
The optics thermistor is open.
Possible causes:
• Optics thermistor open
NOTE: When the optics thermistor is shorted, no SC code is indicated.
The exhaust fan rotates quickly and continuously.

SC191 - Scanner motor thermistor open

Definition: [level: D]
The scanner motor thermistor is open.
Possible causes:
• Scanner drive motor defective
NOTE: The scanner motor thermister is within the scanner motor.
1.6 MAIN CHARGE
SC302 - Charge corona leakage
Definition: [level: D]
The charge power pack detects a charge corona leakage (output: 0V) for 4.8
msec, or detects the output to be more than 7 kV, 10 times in one job.
Possible causes:
• Main charge corona unit defective
• Main charge power pack defective
• High voltage control board defective

SC303 - Charge corona wire cleaner failure

shooting
Definition: [level: C] Trouble-
The current of the charge corona wire cleaner drive motor is over the
specified current within 4 seconds after the cleaner motor starts.
The charge corona wire cleaner does not move back to the end block within
30 seconds.
Possible causes:
• Charge corona wire cleaner drive motor defective
• Insufficient lubrication for the charge corona wire cleaner drive
mechanism (G501 grease)
• High voltage control board defective

FSM 6-7 A095/A096/A097

Rev. 10/94

1.7 DEVELOPMENT
SC341 - Development motor locked
Definition: [level: D]
Development motor OL (overload) signal stays low more than 1 second in
development motor on condition.
Possible causes:
• Extra load in the development unit
• Development motor defective
• Main control board defective

SC342 - Toner collection motor locked

Definition: [level: D]
The toner collection sensor output does not change (OFF → ON or ON →
OFF) for more than 2.55 seconds in the toner collection motor on condition.
Possible causes:
• Toner collection sensor defective
• Toner collection motor defective
• Toner clog in the toner collection pipe

SC343 - Toner collection bottle at improper position

Definition: [level: D]
Toner bottle set switch is off and the front door is closed.
Possible causes:
• Toner collection bottle set switch defective
• Toner collection bottle is set incorrectly

1.8 PROCESS SENSOR

SC351 - Abnormal Vsg Detection (Vsg > 4.2V)
Definition: [level: C]
The detected Vsg value is over 4.2 V.
Possible causes:
• ID sensor defective
• Main control board defective

A095/A096/A097 6-8 FSM

SC352 - Incomplete TD sensor initial setting
Definition: [level: C]
The output voltage of the TD sensor is higher than 2.6 V or lower than 2.4 V
during the developer initial setting mode.
VOUT to get 2.5 V for the TD sensor output is higher than 10 V or lower than
2 V.
Possible causes:
• Connector [A] not set correctly
• Toner density sensor defective
• Abnormal toner concentration

[A]

SC353 - Abnormal Vsp Detection (Vsp ≥ 2.5 V: lighter pattern)

Definition: [level: C]
Vsp is 2.5 V or higher.
Possible causes:
• ID sensor defective
• OPC drum
• High voltage control board defective
• Poor contact of the development bias terminal

SC354 - Abnormal Vsg detection (Vsg ≤2.5 V)

shooting
Definition: [level: C] Trouble-
Vsg is 2.5 V or less.
Possible causes:
• ID sensor defective
• OPC drum
• Dirty charge corona casing
• Quenching lamp defective
• Erase lamp defective
• Cleaning blade defective
• Dirty ID sensor

FSM 6-9 A095/A096/A097

SC355 - Abnormal VTD detection (VTD ≥ 4 V)
Definition: [level: C]
VTD is 4 V or higher.
Possible causes:
• Toner density sensor defective
• Toner concentration too low

SC356 - Abnormal VTD detection (VTD < 0.5 V)

Definition: [level: C]
VTD is less than 0.5 V.
Possible causes:
• Toner density sensor defective
• Toner concentration is too high

SC357 - Abnormal Vsp detection (Vsp/Vsg ≥ 25%)

Definition: [level: C]
Vsp/Vsg is 25% or higher.
Possible causes:
• ID sensor defective
• OPC drum
• Dirty ID sensor

SC358 - Abnormal Vsp detection (Vsp/Vsg < 2.5%)

Definition: [level: C]
Vsp/Vsg is less than 2.5%.
Possible causes:
• ID sensor defective
• OPC drum
• Toner scattering

A095/A096/A097 6-10 FSM

Rev. 4/15/94
SC361 - Incomplete drum potential sensor calibration
Definition: [level: C]
When the process control initial setting is performed and -100 V or -800 V is
applied to the drum shaft, the drum potential voltage is out of range if the
following is true: V100 is over 0.7V or under 0.1V or if V800 rises over 4.2V
or falls under 2.7V.
.
Possible causes:
• Drum potential sensor defective
• High voltage control board defective
• Drum shaft terminal not grounded
• OPC drum
• Main charge corona unit defective

SC364 - Abnormal VD detection

Definition: [level: C]
VD is out of specification (VR + 770 ± 20 V).
Possible causes:
• Drum potential sensor defective
• OPC drum
• Main charge corona unit defective

SC365 - Abnormal VL detection

Definition: [level: C]
VL is out of specification (VR + 140 ± 20 V).
Possible causes:
• Drum potential sensor defective
• OPC drum

shooting
Trouble-
• Main charge corona unit defective
• Optics too dirty

FSM 6-11 A095/A096/A097

Rev. 10/94
1.9 TRANSFER CURRENT
SC402 - Transfer current leakage
Definition: [level: D]
When the transfer power pack output voltage exceeds 4.5 KV for 200 msec
or more, the output current is multiplied by 0.8. If this condition occurs 11
times in a row, an SC is displayed.
Possible causes:
• Transfer belt defective
• Transfer power pack defective
• Poor contact at transfer bias roller, discharge plate terminals
• High voltage control board defective

1.10 DRUM
SC440 - Abnormal main motor speed
Definition: [level: D]
OL (overload) signal stays low in the main motor on condition for 1.0 second
or more.
Possible causes:
• Main motor defective

SC442 - Drum thermistor open

Definition: [level: D]
The drum thermistor is open.
Possible causes:
• Drum thermistor defective

A095/A096/A097 6-12 FSM

Rev. 10/94
1.11 PAPER FEED
SC500 - Abnormal manual feed drive motor speed
Definition: [level : D]
OL (overload) signal stays low in the manual feed motor on condition for 1.0
second or more.
Possible causes:
• Manual feed motor defective

SC501 - Abnormal paper feed drive motor speed

Definition: [level: D]
OL (overload) signal stays low in the paper feed motor on condition for 1.0
second or more.
Possible causes:
• Paper feed motor defective
• Paper feed control board defective

SC502 - Abnormal 1st lift motor movement

Definition: [level: B]
The 1st lift sensor detects high condition for 10 seconds or more after the 1st
lift motor starts. The first time, after the paper tray is opened and closed, the
1st lift motor starts again. If the above condition occurs twice, this SC is
displayed.
Possible causes:
• 1st lift sensor shorted
• 1st lift motor defective
• Paper feed control board defective

SC503 - Abnormal 2nd lift motor movement

shooting
Definition: [level: B] Trouble-
The 2nd lift sensor detects the high condition for 10 seconds or more after
the 2nd lift motor starts. The first time, after the paper tray is opened and
closed, the 2nd lift motor starts again. If the above condition occurs twice, this
SC is displayed.
Possible causes:
• 2nd lift sensor shorted
• 2nd lift motor defective
• Paper feed control board defective

FSM 6-13 A095/A096/A097

Rev. 10/94
SC504 - Abnormal 3rd lift motor (1.5 K LCT motor for A096 and A097
copier) movement
Definition: [level: B]
The 3rd lift sensor detects the high condition for 10 seconds or more after the
3rd lift motor starts. The first time, after the paper tray is opened and closed,
the 3rd lift motor starts again. If the above condition occurs twice, this SC is
displayed.
Possible causes:
• 3rd lift sensor shorted
• 3rd lift motor (1.5 K LCT motor for A096 copier) defective
• Paper feed control board defective

SC506 - Abnormal 3.5 K LCT motor movement

Definition: [level: B]
The LCT lift sensor detects the highcondition for 10 seconds or more after the
LCT motor starts. The first time, after the LCT cover is opened and closed,
the LCT motor starts again. If the above condition occurs twice, this SC is
displayed.
Possible causes:
• LCT motor defective
• LCT lift sensor open

SC507 - Abnormal 3.5 K LCT feed motor movement

Definition: [level: B]
The LCT feed motor OL (overload) siginal stays low for 1 second or more
after this motor starts.
Possible causes:
• LCT feed motor defective

SC508 - Abnormal tandem rear fence drive motor movement

Definition: [level: B]
It takes 10 seconds or more for the rear fence return sensor to detect the on
condition after the rear fence drive motor starts.
It takes 10 seconds or more for the rear fence home position sensor to detect
the on (blocked) condition after this fence starts moving to the home position.
When the tray is set, the rear fence return sensor and the rear fence the
home position sensor are on (blocked).
Possible causes:
• Rear fence drive motor defective
• Rear fence HP sensor defective
• Rear fence return sensor defective

A095/A096/A097 6-14 FSM

Rev. 10/94
SC510 - Abnormal tandem side fence home position detection - stays off
Definition: [level: B]
When the side fence goes back to the home position or the side fence drive
motor works to open the fence, the side fence positioning sensor does not
detect the on (blocked) condition for 5 seconds or more.
Possible causes:
• Side fence drive motor defective
• Side fence positioning sensor open

SC511 - Abnormal tandem side fence home position detection - stays on

Definition: [level: B]
When the side fence goes back to the home position or the side fence drive
motor works to close the fence, the side fence positioning sensor stays on
(blocked) for 5 seconds.
Possible causes:
• Side fence drive motor defective
• Side fence positioning sensor shorted

1.12 DUPLEX
SC520 - Abnormal fusing/duplex drive motor movement
Definition: [level: D]
The OL (overload) signal stays low for 1.0 second after the fusing/duplex
drive motor starts.
Possible causes:
• Fusing/duplex drive motor defective
• Cleaning roller is too dirty and applies a great load to the
fusing/duplex drive motor.

shooting
SC522 - Abnormal jogger home position sensor detection - stays off Trouble-
Definition: [level: B]
The jogger home position sensor does not detect the on (blocked; 5V)
condition for 5 seconds or more after the fusing/duplex drive motor starts.
Possible causes:
• Jogger motor defective
• Jogger HP sensor open

FSM 6-15 A095/A096/A097

Rev. 10/94
SC523 - Abnormal jogger home position sensor detection - stays on
Definition: [level: B]
The jogger home position sensor does not detect the off (unblocked; OV)
condition for 1 second after its sensor detects the on condition in the
initializing mode.
Possible causes:
• Jogger drive motor defective
• Jogger HP sensor shorted

1.13 FUSING
SC541 - Fusing thermistor open
Definition: [level: A]
Detects the fusing thermistor open condition for 2 msec or more after turning
the main switch on.
Possible causes:
• Fusing thermistor open
• Optics control board defective

SC542 - Start key stays red

Definition: [level: A]
The fusing temperature does not reach the specified temperature after 5
minutes from turning the main switch on.
Possible causes:
• Fusing lamp defective
• AC Drive board defective
• Thermofuse defective

SC543 - Fusing overheat (detected by the main control board)

SC544 - Fusing overheat (detected by the optics control board)
Definition: [level: A]
The fusing temperature stays over 231 °C for 5 seconds.
Possible causes:
• AC drive board defective
• Fusing thermistor defective
• Optics control board defective
• Main control board defective

A095/A096/A097 6-16 FSM

Rev. 1/20/94
SC545 - Low fusing temperature (detected by the main control board)
SC546 - Low fusing temperature (detected by the optics control board)
Definition: [level: A]
The fusing temperature stays lower than 100 °C for 5 seconds after the
machine becomes ready.
Possible causes:
• Fusing thermistor defective
• AC drive board defective
• Fusing lamp open
• Main control board defective
• Optics control board defective

SC547 - Fusing lamp continuously lit

Definition: [level: A]
Fusing lamp continuously lights for 70 seconds after the machine becomes
ready. However, if the door is open, paper jams, or the fusing unit is out of
position, the ready condition is canceled and the main relay opens.
Possible causes:
• AC drive board

SC548 - Unstable fusing temperature

Definition: [level: A]
If the fusing temperature changes by 21°C/second four times in 1 minute, this
SC is displayed.
Possible causes:
• AC drive board defective
• Thermistor defective
Countermeasure:
If this occurs, before replacing the optics PCB and main control board, check

shooting
Trouble-
the connection between the main harness and the relay harness (drawer
connector terminals) and the connection between the relay harness and the
thermistor (2P connector).

1.14 SYSTEM CONTROL

SC600 - Communication error (main control board and operation panel)
Definition: [level: D]
The main control board does not communicate with the operation panel.
Possible causes:
• Main control board defective
• Operation panel defective
• Harness defective

FSM 6-17 A095/A096/A097

SC601 - Communication error (main control board and optics control
board)
Definition: [level: D]
The main control board does not communicate with the optics control board.
Possible causes:
• Main control board defective
• Optics control board defective
• Harness defective

SC602 - Communication error (main control board and high voltage

control board)
Definition: [level: D]
The main control board does not communicate with the high voltage control
board.
Possible causes:
• Main control board defective
• High voltage control board defective
• Harness defective

SC603 - Main control board malfunction (CPU)

Definition: [level: D]
Communication to the main control board is not completed.
Possible causes:
• Main control board defective

SC620 - Communication error (main control board and DJF/RDH main

board)
Definition: [level: B]
The main board does not communicate with the DJF/RDH main board.
Possible causes:
• Main control board defective
• DJF/RDH main board defective
• Harness defective
• Fiber optics defective

A095/A096/A097 6-18 FSM

Rev. 4/15/94
SC621 - Communication error (main control board and sorter staplers
(A374/A377)/finisher main board)
Definition: [level: D]
The main control board does not communicate with the sorter stapler
(A374/A377)/finisher main board.
Possible causes:
• Main control board defective
• Sorter stapler(A374/A377)/finisher main board defective
• Harness defective
• Fiber optics defective

1.15 DUAL JOB FEEDER/RECIRCULATING DOCUMENT

HANDLER
SC700 - Abnormal DJF/RDH feed-in motor movement
SC701 - Abnormal DJF/RDH transport belt motor movement
SC702 - Abnormal DJF/RDH feed out motor movement
SC703 - Abnormal RDH inverter motor movement
Definition: [level: B]
Encoder pulse is not detected by the DJF/RDH main board in the main motor
on condition. The first time, a jam occurs. The second time, an SC is
displayed.
Possible causes:
• DJF/RDH feed motor defective
• DJF/RDH transport motor defective
• DJF/RDH feed out motor defective
• RDH inverter motor defective

1.16 FINISHER / SORTER STAPLER

SC730 - Abnormal *transport motor (A374, A377 sorter staplers / A379

shooting
finisher) movement Trouble-
Definition: [level: D]
When the encoder pulse is not detected by the SS (or finisher) main board for
200 msec after the *transport motor starts, a jam is displayed. If this occurs
twice, an SC is displayed.
Possible causes:
• *Transport motor

A374 A377
A379 Finisher
Sorter Stapler Sorter Stapler
Transport drive
* Roller drive motor Main motor
motor

FSM 6-19 A095/A096/A097

SC731 - Abnormal bin drive (lift) motor movement
(A374, A377 sorter staplers)
Definition: [level: B]
If the wheel sensor (bin lift timing sensors) does not change 2 seconds after
the bin drive (lift) motor starts, jam "R2" is indicated.
If the condition above occurs twice, an SC is displayed.
Possible causes:
• Wheel sensor (bin lift timing sensors) defective
• Bin drive (Lift) motor defective

SC732 - Tray shift motor (A379 Finisher)

Definition: [level: B]
The shift tray half turn sensor does not detect the on (blocked) condition for 2
seconds after the finisher tray shift motor starts.
The first time, a jam is indicated. The 2nd time, an SC is displayed.
Possible causes:
• Tray shift motor defective
• Shift tray half turn sensor defective

SC733 - Shift tray lift motor (A379 finisher)

Definition: [level: B]
Stack height sensors 1 or 2 do not detect the on (blocked) condition for the
specified time after the finisher shift tray lift motor.
Possible causes:
• Shift tray lift motor defective
• Stack height sensor 1 or 2 defective

A095/A096/A097 6-20 FSM

SC735 - Abnormal jogger motor movement
(A374, A377 sorter staplers / A379 Finisher)
Definition: [level: B]
When the jogger moves back to the home position, the jogger home position
sensor does not detect the on (blocked) condition within 650 pulses. Then, a
jam is indicated.
When the jogger moves from the home position forward, and moves back to
the home position, the jogger home position sensor does not detect the on
(blocked) condition within 100 pulses. Then, a jam is indicated.
If the above condition occurs twice, an SC is displayed.
Possible causes:
• Jogger motor defective
• Jogger home position sensor defective

SC737 - Abnormal gripper motor movement (A374, A377 sorter staplers)

Definition: [level: B]
When the gripper moves to the staple position, the gripper home position
sensor does not detect the off (unblocked) condition. Then a jam is indicated.
When the gripper moves from the staple position to the bin position, the
gripper home position sensor does not detect the on (blocked) condition
within 1070 pulses. Then a jam is indicated.
When the gripper moves to the home position, the gripper home position
sensor does not detect the on (blocked) condition within 1.25 seconds. Then
a jam is indicated.
When the gripper moves from the home position forward, and moves back to
the home position, the gripper home position does not detect the on condition
within 500 msec or more. Then a jam is indicated.
If the above condition occurs twice, an SC is displayed.
Possible causes:

shooting
Trouble-
• Gripper motor defective
• Gripper home position sensor defective

FSM 6-21 A095/A096/A097

SC738 - Abnormal staple motor movement (A374, A377 sorter staplers)
Definition: [level: B]
The staple home position sensor does not detect a change in state within 600
msec after the motor starts. First a jam is indicated. If this occurs twice, this
SC is displayed.
Possible causes:
• Staple unit (staple motor) defective
• Staple is jammed in the staple unit.

SC740 - Abnormal staple unit drive motor movement

(A377 sorter stapler / A379 finisher)
Definition: [level: B]
The staple unit home position sensor does not detect the on (blocked)
condition when the staple unit is in the home position. A jam is indicated.
The staple unit home position sensor does not detect the on (blocked)
condition (within 1640 pulses) when the staple unit moves to the home
position. A jam is indicated.
The staple unit home position sensor does not detect the on (blocked)
condition (within 280 pulses) when the staple unit moves forward from the
home position and moves back to the home position. A jam is indicated.
If the above conditions occurs twice, this SC is displayed.
Possible causes:
• Staple unit drive motor defective
• Staple unit home position sensor defective

SC741 - Abnormal bin rear plate motor movement (A377 sorter stapler)
Definition: [level: B]
When the rear bin plate is open, the bin rear plate open sensor does not
detect the on condition for 750 msec or more after the motor starts. Then a
jam is indicated.
When the rear bin plate is closed, the bin rear plate home position sensor
does not detect the on condition for 750 msec or more after the motor starts.
Then a jam is indicated.
In the initial condition, the bin rear plate open sensor does not detect the on
condition for 1.25 seconds or more after the motor starts. Then a jam is
indicated.
If the above condition occurs twice, this SC is displayed.
Possible causes:
• Bin rear plate drive motor defective
• Bin rear plate open sensor defective
• Bin rear plate home position sensor defective

A095/A096/A097 6-22 FSM

SC742 - Abnormal stack feed out motor movement (A379 finisher)
Definition: [level: B]
No encoder pulses is detected for 500 msec. or more.
Possible causes:
• Stack feed out motor defective

1.17 OTHERS
SC900 - Total counter failure (staying in the off condition)
Definition: [level: D]
The total counter stays in the off condition.
Possible causes:
• Total counter defective

SC901 - Total counter failure (staying in the on condition)

Definition: [level: D]
The total counter stays in the on condition.
Possible causes:
• Total counter defective

SC full used toner bottle

Definition: [level: A]
The toner overflow switch is activated.
Possible causes:
• Toner collection bottle is full
• Toner overflow switch defective
NOTE: Clear the SC full used toner bottle as follows:

shooting
Trouble-
1. While the main switch is on, open the front doors then take out
the toner collection bottle (used toner bottle).
2. Remove the toner collection bottle then empty and clean the
bottle.
3. Install the empty toner collection bottle.
4. Close the front doors.

FSM 6-23 A095/A096/A097

Rev. 4/15/94
2. ELECTRICAL COMPONENT DEFECTS
2.1 SENSORS
NOTE: All photo-interrupters go low (GND) when the actuator is removed
from the gap between the LED and the photo transistor.
Component
CN Condition Symptom (when the main switch turns on)
(Symbol)

Scanner HP Open SC125 is displayed

(S-1) 512-1
Shorted SC121 is displayed
Platen Cover Open APS and AMS do not function correctly.
Position-1 512-7
Shorted
(S-2) –

Open "Original is on the glass" indicator is displayed

Platen Cover even if the original on the glass has already
Position-2 518-1 been removed.
(S-3)
Shorted –
Lens vertical HP Open SC141 is displayed
(S-4) 512-5
Shorted SC140 is displayed
Lens Horizontal Open SC143 is displayed
HP 513-1
Shorted SC142 is displayed
(S-5)

3rd Scanner HP Open SC145 is displayed

511-1
(S-6)
Shorted SC144 is displayed
Open "Paper end" indicator is not displayed even if
By-Pass Paper there is no paper on the by-pass feed table.
End 108-A5
(S-7) Shorted "Paper end" indicator is displayed even if paper
is set on the by-pass feed table.
Open "Guide plate open" indicator is not displayed
Guide Plate even if the guide plate is open.
Position 108-B9
(S-8) Shorted "Guide plate open" indicator is displayed even
if the guide plate is closed.

Jogger HP Open Jogger motor locks (SC522 counts up)

(S-9) 112-A10
Shorted Jogger motor locks (SC523 counts up)
Vertical Open –
Transport 108-A2
Shorted
(S-10) –

Open "Paper Jam T" indicator is displayed even if

Duplex Exit there is no paper.
112-A8
(S-11)
Shorted Whenever a duplex copy is made, "Paper Jam
T" occurs.

A095/A096/A097 6-24 FSM

Component
CN Condition Symptom (when the main switch turns on)
(Symbol)

Open "Paper Jam T" indicator is displayed even if

Duplex there is no paper.
Entrance Sensor 112-A7
(S-12) Shorted Whenever a duplex copy is made, "Paper Jam
T" occurs.
Open "Copies left in the duplex tray...." indicator is
Duplex Paper displayed even if there is paper in the duplex
End 112-A9 tray.
(S-13)
Shorted Only one rear side copy is made regardless of
the quantity of copies.
Open "Paper Jam T" indicator is displayed even if
Duplex there is no paper.
Transport 109-A4
(S-14) Shorted Whenever a duplex copy is made, "Paper Jam
T" occurs.
Open "Paper Jam E" indicator is displayed even if
Exit there is no paper.
(S-15) 109-A2
Shorted Whenever the copy is fed out, "Paper Jam D"
occurs.
Open "Paper Jam D" indicator is displayed even if
Fusing Exit there is no paper.
(S-16) 109-B7
Shorted Whenever a copy is made, "Paper Jam C and
D" occurs.
Open –
Paper Guide
(S-17) 109-B4 Shorted Whenever a duplex copy is made, "Paper Jam
T" occurs.
Auto Image Open
Density 507-1 Image density will be abnormal.
Shorted
(S-18)

Original Open The CPU cannot properly detect original size.

508-8, 9,
Length-1 APS and AMS do not function correctly.
10 Shorted
(S-19)

shooting
Original Open The CPU cannot properly detect original size. Trouble-
Length-2 509-3, 4, 5 APS and AMS do not function correctly.
Shorted
(S-20)

Original Width Open The CPU cannot properly detect original size.
(S-21) 508-3, 4, 5 APS and AMS do not function correctly.
Shorted
Open The CPU recognizes that the paper width is
By-Pass Paper 319 mm regardless of the side fence position.
Size 114-6
(S-22) Shorted The CPU recognizes that the paper width is
100 mm regardless of the side fence position.

Toner Density Open Machine quits auto toner supply mode and
(S-23) 114-3 enters fixed supply mode.
Shorted

FSM 6-25 A095/A096/A097

Component
CN Condition Symptom (when the main switch turns on)
(Symbol)

Open "Paper Jam C" indicator is displayed even if

Registration there is no paper.
(S-24) 108-A7
Shorted Whenever a copy is made, "Paper Jam C"
occurs.
Open Toner is added even if there is too much toner
Toner End in the toner hopper.
(S-25) 108-B14
Shorted Toner is not supplied even if there is no toner
in the toner hopper.
Open The machine does not exit "Screen Saver"
Auto- mode even if an operator approaches the
Response 113-B3 machine.
(S-26)
Shorted "Screen Saver" mode does not work.

Drum Potential Open Machine quits auto process control and enters
(S-27) 110-10 fixed toner supply mode.
Shorted

Image Density Open Machine quits auto toner supply mode and
(S-28) 111-3 enters detect mode.
Shorted
Open "Paper end" indicator is not displayed even if
1st Paper End there is no paper on the paper tray.
(S-29) 401-A5
Shorted "Paper end" indicator is displayed even if paper
is set.
Open "Paper near end" indicator is not displayed
1st Paper Near even if the tray is almost empty.
End 412-A2
(S-30) Shorted "Paper near end" indicator is displayed even if
there is enough paper on the paper tray.
Open Whenever paper is fed, it is folded.
1st Paper Feed
(S-31) 402-A1 Shorted "Paper jam A" indicator is displayed even if
there is no paper.
Open "Paper near end" indicator is not displayed
2nd Paper Near even if the tray is almost empty.
End 412-A5
(S-32) Shorted "Paper near end" indicator is displayed even if
there is enough paper on the paper tray.
Open "Add paper" indicator is displayed even if there
1st Lift is paper on the tray.
401-A2
(S-33)
Shorted The tray bottom plate locks at the upper
position.
Open "Paper end" indicator is not displayed even if
2nd Paper End there is no paper on the paper tray.
(S-34) 401-B5
Shorted "Paper end" indicator is displayed even if paper
is set.
Toner Collection Open
Motor 412-B5 SC342 is displayed.
Shorted
(S-35)

A095/A096/A097 6-26 FSM

Rev. 10/94
Component
CN Condition Symptom (when the main switch turns on)
(Symbol)

Open "Add paper" indicator is displayed even if there

2nd Lift is paper on the tray.
(S-36) 401-B2
Shorted The tray bottom plate locks at the upper
position.
Open "Add paper" indicator is displayed even if there
3rd Lift is paper on the tray.
(S-37) 403-A2
Shorted The tray bottom plate locks at the upper
position.
3rd Paper Near Open "Paper near end" indicator is not displayed
End even if the tray is almost empty.
(A095 copier 412-A8
Shorted "Paper near end" indicator is displayed even if
only)
there is enough paper on the paper tray.
(S-38)

Open "Paper end" indicator is not displayed even if

3rd Paper End there is no paper on the paper tray.
(S-39) 403-A5
Shorted "Paper end" indicator is displayed even if paper
is set.
Open Whenever paper is fed, it is folded.
3rd Paper Feed
402-A8 Shorted "Paper jam A" indicator is displayed even if
(S-40)
there is no paper.
Open Whenever paper is fed, it is folded.
2nd Paper Feed
402-B1 Shorted "Paper jam A" indicator is displayed even if
(S-41)
there is no paper.

Base Plate Open The bottom plate lift lever locks at the lowest
Down position.
(A096 and A097 404-A10 Shorted The bottom plate is not lowered when paper on
copier only)
the left tray shifts to the right tray and paper is
(S-42)
set in the improper position.
Side Fence Open SC510 is displayed
Positioning
Shorted SC511 is displayed

shooting
Trouble-
(A096 and A097 404-A13
copier only)
(S-43)

Rear Fence Open When the rear fence reaches the return
Return position, the rear plate locks there then SC508
(A096 and A097 404-B10 is displayed.
copier only)
Shorted SC508 is displayed.
(S-44)

Rear Fence HP Open SC508 is displayed.

(A096 and A097
404-B6 Shorted When the rear fence reaches the return
copier only)
position, SC508 is displayed.
(S-45)

FSM 6-27 A095/A096/A097

Rev. 10/94
Component
CN Condition Symptom (when the main switch turns on)
(Symbol)

Left Tandem Open The rear fence moves back and forth
Paper End continuously.
(A096 and A097 404-B12
Shorted The paper on the left tray is not moved to the
copier only)
right tray.
(S-46)

LCT Near End Open "Paper near end" indicator is not displayed
(A096 and A097 even if the tray is almost empty.
copier only) 412-A7
Shorted "Paper near end" indicator is displayed even if
(S-47)
there is enough paper on the paper tray.

Tray Down Open When the bottom plate is lowered, it locks at

(A096 and A097 the lowest position.
403-B2
copier only)
Shorted "Paper end" indicator is displayed even if there
(S-48)
is paper on the tray.

Tray Paper Set Open The bottom plate raises & lowers even if no
(A096 and A097 paper is set.
copier only) 412-A11
Shorted The bottom plate does not raise even if paper
(S-49)
is set on the tray.

A095/A096/A097 6-28 FSM

Rev. 10/94
2.2 SWITCHES
Component CN No. Condition Symptom
"Open the by-pass tray"
indicator is displayed even if
Open the by-pass tray is opened.
By-Pass Table
108-B11 Print key stays red.
(SW-1)
By-pass feed motor
Shorted
continuously turns.
"Close the door" indicator lights
Open
Front Door Safety even if the front door is closed.
–
(SW-2) Copier does not turn off when
Shorted
the front doors are open.
When the 1st tray is selected,
Open
1st Tray Set SC502 is displayed.
(A095 copier only) 407-B8 The 1st tray cannot be selected
(SW-3) Shorted even if the 1st tray is set in the
machine.
Open The CPU cannot detect proper
2nd Paper Size
407-A2 ~ A6 paper size, and misfeeds may
(SW-4) Shorted occur when a copy is made.
SC "Full Used Toner Bottle"
Open indicator lights even if the toner
Toner Overflow bottle is not full.
412-B9
(SW-5) SC "Full Used Toner Bottle"
Shorted indicator does not light even if
the toner bottle becomes full.
No caution is displayed on the
Toner Collection Open LCD even if the toner collection
Bottle Set 412-B7 bottle is set incorrectly.
(SW-6)
Shorted SC343 is displayed.
Lower Front Whenever paper is fed from the
Open
Door Safety 410-1 tray unit, SC501 is displayed.
(SW-7) Shorted —
When the 3rd tray is selected,

shooting
Trouble-
Open
3rd Tray Set SC504 is displayed.
(A095 copier only) 407-B1 The 3rd tray cannot be selected
(SW-8) Shorted even if the 3rd tray is set in the
machine.
Main Open The copier does not turn on.
—
(SW-9) Shorted The copier does not turn off.
Tray Down The 3rd tray bottom plate stays
Open at the lowest position.
(A096 and A097
402-B14
copier only) The 3rd tray bottom plate stays
(SW-10) Shorted at the highest position.

FSM 6-29 A095/A096/A097

Rev. 12/93
2.3 FUSES
2.3.1 DC Power Supply Board

Component Condition Symptom

Power is not provided when the main
FU801 (125 V, 10 A) Open switch is on (No indicator displayed 120VAC
on the operation panel).
Power is not provided when the main
FU802 (125 V, 5 A) Open switch is on (No indicator displayed 5VDC
on the operation panel).

When the 3rd feed station is selected,

FU803 (125 V, 6.3 A) Open 40VDC
SC125 is displayed.

When the main switch is turned on,

FU804 (125 V, 6.3 A) Open SC900 is displayed. 24VDC

When each feed station is selected,

the following indication is displayed:
1st: SC510 or misfeed
FU805 (125 V, 6.3 A) Open 2nd: Add Paper 24VDC
3rd: SC504 or misfeed
When the paper is fed from the
By-pass or LCT. SC342 is displayed.

DJF (RDH) and Sorter Stapler

FU806 (125 V, 6.3 A) Open 24VDC
(Finisher) do not operate.

A095/A096/A097 6-30 FSM

Rev. 1/20/94
3. COPY QUALITY
1. Dark copy/dirty background
SYMPTOM:
If the machine is moved from a cold location to a warm location and the main
switch is turned "ON" immediately, dark copies or copies with a dirty
background may be produced followed by several light copies.
CAUSE:
If condensation accumulates on the optics or drum because of a sudden
temperature change, less light reaches the drum during the process control
data initial setting. The machine sets up for a lighter image density.
If condensation accumulates on the optics, a dark copy appears. If
condensation accumulates on the drum, a dirty background copy appears.
After some time, when the condensation on the optics evaporates or the
condensation on the drum is removed by copy paper going through the
copier, the machine will return to the normal condition and light copies
appear.
SOLUTION:
Wipe off the condensed water on the optics and drum, then perform the
process control data initial setting.
2. Uneven image density just after installation
SYMPTOM:
Just after installation (up to 50 ∼ 100 copies), the image density (solid image)
at the front and the rear is lighter than the image density at the center.

shooting
Trouble-

CAUSE: Lighter Lighter

Due to the design of the new toner hopper, the toner is filled from the front to
the rear. It takes time to completely fill the toner hopper. Therefore it takes
about 50 to 100 copies to evenly supply toner to the toner supply roller.
Also, the toner supply roller width is 210mm, which is narrower than wide
size paper such as A4 sideways (297mm) and letter sideways (279mm).
Therefore, image density tends to be lighter especially at the sides.

FSM 6-31 A095/A096/A097

Rev. 1/20/94
SOLUTION:
Make 50 ~ 100 copies to fully supply the toner into the toner hopper. Stop
the machine every 10 copies to allow the machine to create the ID sensor
pattern to maintain precise toner density.
3. Dirty background
SYMPTOM:
If the customer does not turn off the machine at all, dirty background might
appear on copies.
CAUSE:
The process control data initial setting is only performed when the machine
is turned "ON".
SOLUTION:
Instruct the customer to turn off the main switch at the end of the day (turn
off the machine for at least 30 minutes; fusing temperature should be lower
than 100 degrees centigrade).

4. Distorted vertical lines

SYMPTOM:
Vertical lines are sometimes distorted if the original is not completely
pressed against the exposure glass by the platen cover or DJF/RDH.
Note: This is the same situation as previous models (FT5590 series,
FT6750).
SOLUTION:
Instruct the customer to press the original against the exposure glass by
using a weight, such as a paper package.
5. DJF Original Skew
SYMPTOM:
If original skews occur as illustrated and the DJF height is correctly
adjusted, perform the following adjustment.

A095/A096/A097 6-32 FSM

Rev. 5/94
CAUSE:
The speed of the transport belt is faster than the feed-in motor speed, even if
both motor speeds are within specification.
SOLUTION:
1. Feed-in motor speed adjustment
Adjust the feed-in motor speed so that the motor speed becomes higher
(within specification).
1. Turn DIP SW 101-1,2,4 to "ON".
2. Turn DIP SW 102-1 to "ON".
3. Turn VR 103 toward "H" to turn LED 101 (Red) on.
4. Turn VR 103 toward "L" to turn LED 102 (Green) on.
2. Transport belt motor speed adjustment
1. Turn DIP SW 101-1,2,4 to "ON".
2. Turn DIP SW 102-2 to "ON".
3. Turn VR 104 toward "L" to turn LED 103 (Red) on.
4. Turn VR 104 toward "H" to turn LED 102 (Green) on.
6. Light Copies
SYMPTOM:
Light copies - toner hopper becomes empty - "Toner End" indication.
CAUSE:
Defective Toner End Sensor.
Normally, the mylar [A] on the toner hopper agitator shaft scrapes the Toner
End Sensor Surface [B] to keep the surface clean. However, if the pressure
between the sensor and the mylar is too high, the sensor may be damaged.
If this occurs, the machine judges that there is toner in the hopper even if the
hopper is empty. [A]

Solution:
[A]
We recommend performing step (2) of
this countermeasure at machine setup /
installation. [B]

(1) Replace the Toner End Sensor [A]

shooting
Trouble-
(P/N AW31 0003).
[B]
(2) Since replacement of the cleaning mylar
is impossible, add (2) 0.5mm washers [B]
as shown (P/N 0708 0030B: thickness =
0.5mm inner diameter = 3.2mm, outer
diameter = 6mm). This will reduce the
pressure between the Toner End Sensor
and the cleaning mylar. [A]

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after
serial number A33544200001 & A3364420032 respectively will have a new
Toner End Sensor Cleaning Mylar installed during production to prevent the
above mentioned symptom.

FSM 6-33 A095/A096/A097

Rev. 1/20/94
4. MISFEEDS
SYMPTOM:
Fusing paper jam
CAUSE:
Solid image at the leading edge on the back side of the paper sticks to the
pressure roller and will not separate resulting in a fusing jam.
SOLUTION:
Instruct the customer to select the edge erase mode.
SYMPTOM:
Sorter Stapler entrance jam
CAUSE:
The mylar (illustrated below) is out of position.

No good
SOLUTION: Good

Set the mylar in the correct position without buckling, curling or waving.
SYMPTOM:
Originals stick to the exposure glass (FT6645 only)
CAUSE:
Static electricity built up on the exposure glass
SOLUTION:
Apply a small amount of silicone oil on the exposure glass.
If this problem occurs frequently because of the kind of originals the
customer uses, install the FT6655 type exposure glass which has an
antistatic coating as a special countermeasure.

A095/A096/A097 6-34 FSM

Rev. 1/20/94
5. MACHINE CONDITIONS
SYMPTOM:
Toner end condition appears on the LCD just after installing a new machine
with a new toner bottle.
CAUSE:
Due to the design of the toner hopper, it takes a short amount of time to
completely fill it with toner. During this time, it is possible for the toner end
condition to occur. In particular, this tends to happen when continuous
copies are made from a high image density original (example) just after
installation (developer initial setting).
SOLUTION:
Make 50 ~ 100 copies to fully supply the toner into the toner hopper. Stop
the machine every 10 copies to allow the machine to create the ID sensor
pattern to maintain precise toner density.
SYMPTOM:
The copy counter indicates "8" even if another key (for example, the Clear
Modes key) is pressed. For instance, if the Clear Modes key is touched three
times, the copy counter indicates "888".
CAUSE:
The grounding wire terminal is touching the operation panel board circuit
pattern. This may occur after the operation panel is opened to install the
guidance ROM’s at installation. If the grounding wire is pulled strongly, the
terminal may be rotated and bent. If the bent terminal is pressed against the
insulating sheet and touches the legs of electrical elements behind the
insulating sheet, a short-circuit may result.

shooting
Trouble-

Good No good

SOLUTION:
Correct the bent terminal and repair the insulating sheet with insulating tape
such as teflon tape.

FSM 6-35 A095/A096/A097

Rev. 7/11/94
SYMPTOM:
PCB’s and/or Power Pack damage.
CAUSE:
When units such as the drum unit or transfer belt unit are removed while the main switch is
turned "ON", electrical noise or surge current might occur resulting in PCB damage.
SOLUTION:
Replace the damaged PCB or Power Pack.

CAUTION: Turn "OFF" the main switch before disconnecting the

connector or removing the unit

SYMPTOM:
The Sorter Stapler does not staple even if the staple mode is selected.
CAUSE:
If direct sunlight strikes the bin jam sensor to (a photo transistor), it causes the sensor to
malfunction and disregard the staple command.
SOLUTION:
1. Avoid installing the machine in direct sunlight.
2. Install a piece of mylar around the bin-jam sensor to protect it from direct sunlight.

SYMPTOM:
SC502, 508, 510, 511
CAUSE:
1. When the tandem paper tray is closed roughly, it bounces slightly to the front
disengaging the drawer connectors.
2. When the customer pulls out the tandem tray to clear a misfeed, paper may drop behind
the tray. The paper is then caught in the drawer connector at the rear side of the right
tandem tray when the tray is pushed back in.
SOLUTION:
1. Instruct the operator to gently push the tandem tray until it stops. If any of the above
mentioned Service Codes are present, instruct the operator to pull the tray out and gently
push the tray back in until it stops and then turn the main switch "OFF" and then "ON".
Apply silicone grease (G-501) to the points called out in the illustrations below. This
reduces the friction between the tandem tray and the guide rail which helps the lock lever
to position the tandem tray at the correct position. If the tandem tray bounces slightly to
the front, the lock lever pushes the lock plate to move the tray back to the correct
position.

Grease
Grease

A095/A096/A097 6-36 FSM

Rev. 7/11/94
2. To ensure paper is not trapped behind the tandem tray, the paper guide seal
(P/NA0966694) and the paper guide sheet (P/NA0966693 have been added.

Paper Guide Seal

Tandem Tray
Paper Guide Sheet

Upper Front Stay

NOTE: The Paper Guide Sheet prevents paper from being caught by
the upper front stay.

INSTALLATION PROCEDURE:
Paper Guide Seal
Paper Guide Seal
1. Peel of the seal.
[A]
2. Adhere the guide seal as shown.

Paper Guide Sheet

shooting
1. Peel off the seals [A]. Trouble-
2. Adhere the guide sheet [B] as shown.

[B]

FSM 6-37 A095/A096/A097

Rev. 4/4/94
SYMPTOM:
1. The scanner overruns home position and contacts the optics frame.
2. The exposure lamp turns off suddenly and the scanner stops during copying causing the
copy paper to stop in the fusing unit. A partially black solid image appears on the copy
paper because the exposure lamp has turned off during the copy process.
3. When the above mentioned fuser jam is removed, the selected copy modes are cleared.
4. The erase lamp turns on at the wrong time and position resulting in partially void copy
image.

CAUSE:
Poor ground connection at one or more of the following points:

1. By-pass paper size sensor bracket 6. Main corona unit

2. Development unit grounding spring 7. Fusing roller anti-static brush
3. Development unit grounding spring plate 8. Drum shaft grounding terminal
4. ID sensor board bracket 9. Cleaning brush roller grounding
5. Pick-off pawl shaft

SOLUTION:

Ensure proper grounding at all of the following points:

1. The ground wire [A] at the by-pass paper size sensor [B].

[A]

[B]

A095/A096/A097 6-38 FSM

Rev. 4/4/94
2. The grounding spring [C] at the grounding plate [D] (this prevents excessive static
charge generated by the developer from arcing between the development unit and the
registration guide plate)

[D]

[C]

NOTE: From December 1993 production, the grounding spring inner

diameter has been reduced so that it is properly secured and
positioned by the stepped screw.
3. The grounding spring plate [A] to the development unit

Development unit
[A]

4. The ID sensor to the ID sensor board bracket via the ground strap (this prevents static
electricity from arcing between the copy paper and the ID sensor board bracket).

Pick-off Pawl shaft

Tension Spring
Ground Strap

shooting
ID Sensor Board Bracket
Trouble-

5. The pick-off pawl tension spring (above) has been electrically connected to the ID sensor
board bracket since the first production machines in December, 1993 (this prevents
arcing between the copy paper and the pick-off pawl shaft).

FSM 6-39 A095/A096/A097

Rev. 4/4/94
Spring replacement procedure

[B]
[A]

[C]
[D]

1) Remove the ID sensor Bracket [C] (2 screws).

2) Remove the old tension spring (1 E-ring).
3) Install the new tension spring (1 E-ring)
4) Re-install the ID sensor board bracket. Secure the hook [D] at the
end of the spring to the screw fixing the ID sensor board bracket.

6. Ensure the main charge corona is set properly and is secured to the drum
stay with a screw (this prevents poor contact at the rear terminal which could
result in high voltage leakage).

7. The anti-static brush [A] must be in contact with the edge of the fusing
roller (this prevents static from accumulating on the fusing roller and arcing
to nearby metal parts).

[A]

Fusing Unit

A095/A096/A097 6-40 FSM

Rev. 4/4/94
8. If the drum shaft grounding terminal [B] is not set properly or has too much wear (does
not contact the drum shaft), incomplete grounding may occur (this results in electrical
malfunction).

[B]

NOTE: The drum shaft grounding terminal should be replaced every

360k copies.

9. If the grounding wire [A] is not installed correctly, static charge on the cleaning brush
may arc to nearby parts (this results in electrical malfunction).

[A]

shooting
Trouble-

FSM 6-41 A095/A096/A097

Rev. 7/11/94
SYMPTOM:
The Touch Panel keys do not respond when touched.

CAUSE:
Rough adjustment of Touch Panel display positioning.

SOLUTION:
Precisely adjust the Touch Panel display position as follows:

1. Press the Interrupt key then press and hold the Clear/Stop key for
more than three (3) seconds. [A]
[B]
C

2. Follow the guidance on the LCD.

2-1.Touch the upper left corner [A].
2-2.Touch the lower right corner [B].

NOTE: When touching the corners, use a small object such as a pen or
pencil point but DO NOT press too hard to avoid damage to the
Touch Panel.

2-3. Touch a few positions to confirm whether the touch panel is correctly
adjusted.
NOTE: When a portion of the Touch Panel is touched, the
corresponding position indicates a "+" mark. If this "+" mark is
more than 7mm away from the precise point touched, press the
Clear/Stop key and start the adjustment procedure from the
beginning.

2-4. If the adjustment is correct, press the Enter key .

NOTE: DO NOT skip step 2-4 of this procedure, otherwise, the result of
the latest adjustment is ignored.

A095/A096/A097 6-42 FSM

Rev. 2/17/95
6. FT6645/6655/6665 ROM MODIFICATION
HISTORY

FT6645/6655/6665 - ROM MODIFICATION HISTORY

DESCRIPTION OF MODIFICATION RICOH P/N QTY SERIAL NUMBER LOCATION
- Prevents the machine from
entering the Screen Saver A0965151B 2 FT6645 - A3355420001 Main
Mode during Auto Counting A0965153B FT6655 - A3365420313 Control
Mode. FT6665 - A3375420001 Board
- Disables operating time
indication for single side original
to duplex copy mode and
increases the accuracy of the
indicated operation time for
duplex original to duplex copy
mode.
- Increase the maximum copy
set for Sort Mode when using
the RDH & Finisher to "999."
- Allows copy paper to exit the
copier in the event of an RDH
misfeed.
- Increases the maximum sorter
bin capacity for 81/2"x11" and
smaller paper from 15 to 30
sheets/bin (ST24/FT6645 only)
- Prevents cover sheets from
being inserted into the middle of
copy job following copier
misfeed.
- Prevents black line on front
edge when the original is fed by A0965151A 2 FT6645 - A335446077 Main
the DJF while in reduction A0965153A FT6655 - A3364460002 Control
mode. FT6665 - from 1st Board
- Ensures the Erase Lamp turns production
"OFF" during a jam indication.
This prevents a horizontal black

shooting
line on copiers due to Drum
overexposure by the Erase Trouble-
Lamp.
- Ensures SC353 and SC357
are counted in SC counter (SP
Mode) only when a malfunction
occurs.

FSM 6-43 A095/A096/A097

DUAL JOB FEEDER
A376
1. SPECIFICATIONS
Original Feed Mode: Automatic document feed mode
Automatic reverse document feed mode
Semi-automatic document feed mode
Mixed sized mode
Pasted original mode
Preset mode
Combine originals mode
Original Size, Weight and
Table Capacity:
40.7
46.5 52.8 64.0 81.4 104.7 128.0
Paper Weight g/m2
11 lb 12.5 14 17 22 28 34
Maximum number of
50 50 50 50 50 30 25
originals to be set
A3 lengthwise ❋ ❋ ● ● ● ❍ ❋
A4 lengthwise ❋ ❋ ● ● ● ❍ ❋
A4/A3 version

A4 sideways ❋ ❋ ● ● ● ❍ ❋
A5 sideways ❋ ❋ ❍ ❍ ❍ ❍ ❋
B4 lengthwise ❋ ❋ ● ● ● ❍ ❋
B5 lengthwise ❋ ❋ ● ● ● ❍ ❋
B5sideways ❋ ❋ ● ● ● ❍ ❋
F (8" x 13") lengthwise ❋ ❋ ● ● ● ❍ ❋
11" x 17" lengthwise ❋ ❋ ● ● ● ❍ ❋
81/2 x 14" lengthwise ❋ ❋ ● ● ● ❍ ❋
81/2 x 11" lengthwise ❋ ❋ ● ● ● ❍ ❋
81/2 x 11" sideways ❋ ❋ ● ● ● ❍ ❋
51/2" x 81/2" lengthwise ❋ ❋ ❍ ❍ ❍ ❍ ❋
51/2" x 81/2" sideways ❋ ❋ ❋ ❋ ❋ ❋ ❋
LT/DLT version

8" x 13" (F) lengthwise ❋ ❋ ● ● ● ❍ ❋

81/2 x 13" (F4)
❋ ❋ ● ● ● ❍ ❋
lengthwise
8" x 101/2" lengthwise ❋ ❋ ● ● ● ❍ ❋
8" x 10" lengthwise ❋ ❋ ● ● ● ❍ ❋
8" x 10" sideways ❋ ❋ ● ● ● ❍ ❋
10" x 14" lengthwise ❋ ❋ ● ● ● ❍ ❋
Dual Job Feeder

11" x 15" lengthwise ❋ ❋ ● ● ● ❍ ❋

A376

●: Mixed Original mode

Preset mode
ADF mode (1 sided originals mode)
ARDF mode (2 sided original(s) mode)
SADF mode
❍: ADF mode, ARDF mode, SADF mode
❋: ADF mode, SADF mode

FSM 7-1 A095/A096/A097

Original Standard Position: Rear left
Original Separation: Feed and friction belt
Original Transport: One flat belt
Power Source: DC24V from the copier, 2.0A (average)
Power Consumption: 70W
Dimensions (W x D x H): 680 x 508 x 116mm
(26.8" x 20.0" x 4.6")
Weight: 13kg (28.7lb)

A095/A096/A097 7-2 FSM

2. COMPONENT LAYOUT
2.1 MECHANICAL COMPONENT LAYOUT

1 2 3 4 5 6 7

12 11 10 9 8

1. Friction Belt 7. Inverter Pawl

2. Original Stopper 8. Inverter Roller
3. Press Roller 9. Transport Belt
4. Side Fence 10. Pick-up Rollers
5. Original Table 11. Pull-out Roller
6. Exit Roller 12. Feed Roller Dual Job Feeder
A376

FSM 7-3 A095/A096/A097

3. ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the attached
Point to Point for symbols and index numbers.

Symbol Name Function Index

No.
Motors
M1 Feed-in Drives the feed-in system 1
(pick-up, feed, pull-out rollers,
separation belts)
M2 Belt Drive Drives the transport belt. 2
M3 Feed-out Drives the feed-out and the 5
inverter system.
Sensors
S1 DF Position Informs the CPU when the DJF 7
is being closed so that original
size detection sensors can
check the original size.
S2 Feed-out Checks for original misfeeds and 8
sets original stop timing when in
auto-reverse mode.
S3 Registration–2 Detects the leading edge of the 10
original to turn off the feed-in
clutch and to change the feed-in,
belt drive motors speed. Also
detects the original length.
S4 Original Width–3 Detects the original width. 11
S5 Original Width–1 Detects the original width. 12
S6 Original Width–2 Detects the original width. 13
S7 Registration–1 Detects the trailing edge of the 14
original to change the belt-drive
motor speed. Also, detects the
original length and original jam.
S8 Original Feed Detects if the originals reach the 15
feed roller or not.
S9 Original Set Detects if the originals are set 16
on the feed table.

A095/A096/A097 7-4 FSM

Symbol Name Function Index
No.
S10 Pulse Count Counts the pulses generated by 19
the pulse generator disc to
determine the original length.

Solenoids
SOL1 Inverter Energizes to invert the original 4
when copying two sided
originals.
SOL2 Stopper Lifts the original stopper and 9
lowers the press roller to feed
the set of originals to the feed
roller.
SOL3 Separation Transmits drive to the 18
separation belts.
PCBs
PCB1 DF Main Board Controls all DJF functions. 3
PCB2 Indicator Panel Contains operator indicators. 21
Board
Switches
SW1 Lift Informs the CPU when the DJF 6
is lifted and also serves as the
jam reset switch for the DJF.
SW2 Feed Cover Detects if the feed cover is 17
closed.
Clutches
MC1 Feed-in Transmits the feed-in motor 20
drive to the pick-up and feed
rollers, and to the separation
belts.
Dual Job Feeder
A376

FSM 7-5 A095/A096/A097

4. INSTALLATION
4.1 ACCESSORY CHECK
Check the accessories according to the following list:
Description Q’ty
1. Installation procedure..............................................................1
2. Stepped screw ........................................................................2
3. Philips screw with flat washer - M5 x 10 .................................2
4. New equipment condition report
(for – 17, – 27 machines only).................................................1
5. Envelope (for – 17 machine only) ..........................................1

A095/A096/A097 7-6 FSM

Rev. 1/20/94
4.2 INSTALLATION PROCEDURE
[A]

[C]

[B]

1. Remove the tape strips and the cushion. When removing the tape [A]
fixing the original press roller shaft [B], confirm that the shaft is correctly
in the holder [C]. It is possible to dislodge the shaft from the holder by
removing the tape as the tape adheres very strongly to the shaft.
NOTE: If the shaft is out of position, the original will not feed.

CAUTION: When installing the Dual Job Feeder (DJF), make sure that
the copier is unplugged.

2. If present, remove the sensor [D] from the copier (1 screw).

[D] Dual Job Feeder

A376

NOTE: Sensor [D] is not installed on copiers just out of their box.

Sensor [D] is an accessory of the platen cover (option).

FSM 7-7 A095/A096/A097

[B]
[A]
[B]

[C]

[E]

[D]

[B]
[B] [F]

3. Install the cover [A] with the screw supplied as an accessory of the
copier.
4. Install two stepped screws [B] to hook the DJF.
NOTE: There is one screw hole available on the left side for one of the
stepped screws. However there are two screw holes available
on the right where the stepped screw is to be installed. Install the
stepped screw into the inner screw hole [C] as shown in the
illustration.
5. Mount the DJF to the two stepped screws [B] by aligning the holes in the
DJF hinge [D] and the stepped screws, then slide the DJF to the front as
shown.
6. Secure the DJF to the copier (2 screws - M 5 x 10).
7. Remove a small cap on the upper rear cover of the copier then connect
the connector [E] and the fiber optic cable connector [F].

CAUTION: Locate the fiber optic cable [F] over the electrical cable[E]
so as not to bend the fiber optic cable[F] while opening
and closing the DJF.

A095/A096/A097 7-8 FSM

[C]

[D]

[A]

[B]

[F]

[E]

8. Adjust the height of the DJF by using the adjusting dials [A]. Repeat the
following procedure for each adjustment dial.
1) Close the DJF.
2) Confirm whether or not the copier upper cover [B] and all four stoppers
[C and D] are in contact.
3) If not, loosen the lower dial [E] (rotate counterclockwise) and adjust
the height of the DJF by rotating the upper dial [F].
NOTE: 1. First, adjust the DJF height so that the two front stoppers [C]
contact the upper cover, then adjust the DJF height so that all
four stoppers [C and D] contact the upper cover [B].
2. Rotate the right adjusting dial clockwise to lower the left front
Dual Job Feeder

side of the DJF (black arrow in the illustration).

3. Rotate the left adjusting dial clockwise to lower the right front
A376

side of the DJF.

4. If the height adjustment is not correct, then original skew will
occur.

FSM 7-9 A095/A096/A097

Rev. 4/15/94

[D]

[C]

[A]
[E]

[B]

4) Lock the adjusting (upper) dials [A] by fully rotating the lock (lower)
dials [B] clockwise.
NOTE: Height should be proper when the gap [C] is 2 mm. If the height
adjustment is not completed even if the gap [C] is less than 3
mm, remove the cover [D] (4 screws), and loosen then tighten 4
screws [E]. Then adjust the height again.

9. Plug in the copier and turn on the main switch.

NOTE: The copier automatically recognizes that the DJF has been
installed.

10. Make copies using the DJF and confirm the copy image.

A095/A096/A097 7-10 FSM

5. SERVICE TABLES
5.1 DIP SWITCHES AND SWITCHES
0: OFF 1: ON ↓: Push
DPS101 DPS102 SW
Modes Function
1 2 3 4 1 2 3 4 101 102
Motor ON 1 1 0 1 1 0 0 0 – – Feed-in motor activates
(speed 1 1 0 1 0 1 0 0 – – Belt drive motor activates
Adj.)
1 1 0 1 0 0 1 0 – – Feed-out motor activates
0 0 1 1 1 0 0 0 0 0 Stopper solenoid activates
MC, SOL 0 0 1 1 0 1 0 0 0 0 Separation solenoid activates
Test
0 0 1 1 0 0 1 0 0 0 Feed clutch activates
0 0 1 1 0 0 0 1 0 0 Reverse solenoid activates
0 1 0 1 0 0 0 0 ↓ 0 Feeds the original (thick mode)
0 1 0 1 0 0 0 1 ↓ 0 Feeds the original (thin mode)
0 1 0 1 0 0 0 0/1 0 ↓ Delivers the original
Original
Feed 0 1 0 1 1 0 0 0 ↓ 0 Feeds the original (2 sided mode)
(Registra- Reverses the original / Exits the
tion Adj.)
0 1 0 1 1 0 0 0 0 ↓
original
Feeds the original (pasted
0 1 0 1 0 1 0 0 ↓ 0
original mode)
Exits the original (pasted original
0 1 0 1 0 1 0 0 0 ↓
mode)
1 0 0 1 0 0 0 0 ↓ 0 Thick / 1 sided original mode
1 0 0 1 0 0 0 1 ↓ 0 Thin / 1 sided original mode
1 0 0 1 1 0 0 0 ↓ 0 Thick / 2 sided original mode
Free run
with original 1 0 0 1 1 0 0 1 ↓ 0 Thin / 2 sided original mode
1 0 0 1 0 1 0 0 ↓ 0 Thick / mixed size original mode
1 0 0 1 0 1 0 1 ↓ 0 Thin / mixed size original mode
1 0 0 1 0 0 1 – ↓ 0 Combine 2 originals mode
1 0 0 1 – – – – 0 ↓ Stops the free run
0 1 1 0 0 0 0 0 ↓ 0 Starts the free run
Free run
0 1 1 0 0 0 0 0 0 ↓ Stops the free run
0 0 0 0 1 0 0 0 – – Shift value +3.5 mm
Original 0 0 0 0 0 1 0 0 – – Shift value +7.0 mm
Distance 0 0 0 0 1 1 0 0 – – Shift value +10.5 mm
Dual Job Feeder

Adj. 0 0 0 0 0 0 1 0 – – Shift value +14.0 mm

(Combine
0 0 0 0 1 0 0 1 – – Shift value –3.5 mm
A376

Originals)
0 0 0 0 0 1 0 1 – – Shift value –7.5 mm
0 0 0 0 1 1 0 1 – – Shift value –10.5 mm
0 0 0 0 0 0 1 1 – – Shift value –14.0 mm
Standard 0 0 0 0 0 0 0 0 0 0 Standard setting

FSM 7-11 A095/A096/A097

5.2 VARIABLE RESISTORS
VR NO. FUNCTION
101 Adjusts the registration in 1 sided original mode
102 Adjusts the registration in 2 sided original mode
103 Adjusts feed-in motor speed
104 Adjusts belt drive motor speed
105 Adjusts feed-out motor speed

5.3 LEDs
LED NO. FUNCTION
101 Monitors the motor speed (too fast)
102 Monitors the motor speed (normal)
103 Monitors the motor speed (too slow)

5.4 FUSEs
FUSE NO. FUNCTION
101 Protects the 5 V line
102 Protects the 12 V line
103 Protects the 24 V line from feed-in motor failure
104 Protects the 24 V line from belt drive motor failure
105 Protects the 24 V line from feed-out motor failure

A095/A096/A097 7-12 FSM

6. REPLACEMENTS AND ADJUSTMENTS
6.1 TRANSPORT BELT REPLACEMENT

[B]
[A]

[C]

[D]

1. Turn off the copier’s main switch.

2. Fully raise the DJF, then remove the front cover [A] (loosen 4 screws).
3. Remove the four screws fixing the transport belt guide assembly [B].
4. Fold the stay [C] as shown.
Dual Job Feeder

5. Remove the transport belt [D].

A376

FSM 7-13 A095/A096/A097

[A]

[B]

[D]

6. Install the new belt to the belt guide assembly [A]. [C]
NOTE: When setting the new belt, set the belt between the belt
guides [B].
7. While opening the original guide [C], install the belt guide assembly to
the DJF (4 screws).
8. Install the front cover [D].
9. Confirm the DJF height. (Refer to step 9 of the installation procedure.)

A095/A096/A097 7-14 FSM

Rev. 1/20/94
6.2 FEED ROLLER REPLACEMENT
[B]

[A]

[E]

[F]
[C] [D]
1. Turn "OFF" the main switch and open the feed cover [A].
2. Replace the guide mylars [B] (1screw each).
3. Remove the snap ring [C].
4. Slide the roller [D] to the rear.
5. Hold the feed roller [E] then slide the shaft to the front, then remove the
feed roller assembly as shown.
6. Remove the four snap rings [F], then remove the feed rollers.
Dual Job Feeder

7. Install the new feed rollers, then re-assemble the machine.

A376

FSM 7-15 A095/A096/A097

[A]

[C] [B]

[D]

[D] [D]

[GOOD] [NO GOOD]

5. Remove the original guide [A] (3 screws).
6. Slide the feed roller assembly [B] to the front, then remove it as shown.
7. Remove the five snap rings [C], then remove the feed rollers.
8. Install the new feed rollers, then re-assemble the machine.
NOTE: 1. When working around the feed rollers, be careful not to
damage the guide mylars [D], and set the guide mylars
correctly as shown.
2. When installing the feed roller, be sure that the one way
bearing (silver color) is located in the front side (the roller
must rotate only counter-clockwise when the shaft is fixed).
3. Do not touch the roller surface with oily hands.
4. After this replacement, adjust the side-to-side original
registration if necessary.

A095/A096/A097 7-16 FSM

6.3 SEPARATION BELT REPLACEMENT
[B]
[A]

[C]

[E]

[D]

1. Turn off the main switch.

2. Fully raise the DJF, then remove the front cover [A] (loosen 4 screws).
3. Remove the screw [B], then remove the feed cover [C].
4. Remove the bracket [D] (1 screw).
5. Remove the four snap rings [E]. Dual Job Feeder
A376

FSM 7-17 A095/A096/A097

[A]

[C]

[D]

[B]

6. Slide the separation belt assembly [A] to the front and remove them.
7. Remove the bushings [B].
8. Remove the pulley [C].
9. Replace the separation belts [D].
NOTE: Do not touch the separation belt with oily hands.

A095/A096/A097 7-18 FSM

6.4 FEED-OUT MOTOR (FEED-OUT UNIT) REMOVAL
[C] [D]

[B]
[A]

[B]

[E]

[F]

[E]
[E] [F]
1. Fully raise the DJF then remove the front cover. (Refer to Transport Belt
Replacement.)
2. Remove the right cover [A] (4 screws).
Dual Job Feeder

3. Remove the two screws [B] fixing the transport belt assembly, then fold
the transport belt stay [C] as shown.
A376

4. Open the original guide [D].

5. Disconnect the four connectors [E].
6. Remove the five screws [F].

FSM 7-19 A095/A096/A097

[A]

[B]
[G]

[C]

[D]

[H]
[E]

[F]

7. Remove the feed-out unit [A] as shown.

8. Remove the spring [B].
9. Remove the bracket [C] with the feed-out motor from the feed-out unit (3
screws).
NOTE: When re-installing the bracket, be sure to set the arm [D] on the
plunger pin [E].
10. Remove the pulley [F] (1 Allen screw [G]).
11. Remove the feed-in motor (4 screws) [H].

A095/A096/A097 7-20 FSM

6.5 INVERTER SOLENOID REMOVAL AND ADJUSTMENT

[B]
[C]

[A]

[D] OFF ON

[E]

ON

OFF
1. Remove the feed-out unit. (Refer to Feed-out Motor Removal.)
2. Remove the inverter solenoid [A] (2 screws).
Dual Job Feeder

NOTE: When installing the inverter solenoid, confirm the following:

1) The arm [B] must be set on the plunger pin [C].
A376

2) Manually pull the inverter solenoid plunger and confirm that

when the inverter solenoid does not activate (OFF), the
inverter guide [D] is inside the outer inverter guide [E] and
when the inverter solenoid activates (ON), the inverter guide
is outside the outer inverter guide, as shown.

FSM 7-21 A095/A096/A097

6.6 BELT DRIVE MOTOR REPLACEMENT
[B]
[A]

[C]
[D]

1. Remove the DJF from the copier (2 screws, 2 connectors, 2 hooks) and
place it on a stable place.

CAUTION: Before disconnecting the connectors, turn off the main

switch of the copier.

2. Remove the motor cover [A] (4 screws).

3. Remove the DF main control board cover [B] (4 screws).
4. Remove the transport belt. (Refer to the The Transport Belt
Replacement.)
5. Remove the right cover [C] (4 screws).
6. Remove the belt guide assembly [D] (6 screws).
NOTE: After re-installing the belt guide assembly, confirm the DJF
height (Refer to the procedure 9 of the Installation Procedure.)

A095/A096/A097 7-22 FSM

[A]

[D] [C]

[B]

[F]

[E]

7. Remove the left hinge stay [A] (4 screws, 3 connectors).

NOTE: When re-installing the hinge stay, be sure not to pinch the
harness.
8. Remove the two connectors [B].
9. Remove the two screws [C] fixing the belt drive motor bracket.
10. While unhooking the pin [D] from the hole on the feed-in motor bracket,
Dual Job Feeder

remove the bracket [E] with the belt drive motor [F].
A376

11. Remove the drive pulley (1 Allen screw) then replace the belt drive motor
(4 screws).

FSM 7-23 A095/A096/A097

[C]
[B]

[D]

[A]

12. Re-assemble the machine.

NOTE: 1) Before installing the belt guide assembly [A] to the DJF, set
the timing belt [B] on the drive pulley [C].
2) Make sure that the timing belt does not touch any harness.
3) Do not bend the anti-static brush [D].

A095/A096/A097 7-24 FSM

6.7 FEED-IN CLUTCH (FEED-IN UNIT) REMOVAL

[B] [A]

[D]

[C]

1. Remove the following parts:

1) Original table [A] (refer to Feed Roller Replacement),
2) Feed cover [B] (refer to Separation Belt Replacement),
3) Left hinge stay [C] (refer to Belt Drive Motor Replacement).

2. Remove the table bracket [D] (2 screws).

Dual Job Feeder
A376

FSM 7-25 A095/A096/A097

Rev. 4/15/94

[B]

[A]

[D]

[E]

[E] [D]
[C]

3. Disconnect all connectors [A].

4. Remove the feed-in unit [B] (4 screws).
5. Replace the feed-in clutch [C] (1 Allen screw).
NOTE: When installing the clutch on the shaft [D], align the surface of
the clutch stopper [E] and the head of the shaft [D], as shown.

A095/A096/A097 7-26 FSM

6.8 STOPPER SOLENOID REPLACEMENT

[C]

[D]
[A]
[B]

[C]

[D]
1. Remove the feed-in unit. (Refer to Feed-in Clutch Replacement)
2. Remove the bracket [A] with the stopper solenoid (2 screws).
3. Replace the stopper solenoid [B] (2 screws).
NOTE: When installing the stopper solenoid, pay attention to the
following points:
1) The spring [C] must be correctly hooked to the stopper [D], as
shown.
2) Manually pull the stopper solenoid plunger to confirm that the
Dual Job Feeder

press rollers firmly contacts the pick-up rollers. When the

pick-up rollers are manually rotated, the press rollers also
A376

rotate. If not, adjust the stopper solenoid position.

FSM 7-27 A095/A096/A097

6.9 VERTICAL REGISTRATION ADJUSTMENT
6.9.1 One Sided Original Mode

[C] [A]

[B]

0 ~ 2 mm
1. Remove the small cover at the rear side on the upper DJF cover.
2. Turn on DIP-SW No. 101-2, 4 and 102-4.
3. Set a sheet of A4 / 8 1/2" x 11" (53 ~ 80 g/m2 / 14 ~ 22 lb)sideways
paper on the original table.
4. Push SW 101 [A].
5. After the original stops on the exposure glass, gently raise the DJF so
that the original does not move.
6. Confirm that the gap between the trailing edge of the paper and the
original left scale [B] is within 2 mm.
7. It the gap is larger than 2 mm, adjust the registration by using the copier
SP mode ( 1 SP Adjustment - PAGE 6).
NOTE: 1. Before setting the original on the original table again, open
and close the feed unit cover [C].
2. After completing the adjustment, return the DIP switches to
the original condition.

A095/A096/A097 7-28 FSM

Rev. 4/15/94
6.9.2 Two Sided Original Mode

[A]

[B]
VR102

10 ± 2 mm

[C]

1. Remove the copier’s left scale [A] (2 screws).

2. Remove the small cover at the rear side on the upper DJF cover then
turn on DIP SW 101-2, 101-4 and 102-1.
3. Set a sheet of A4 / 8 1/2" x 11" (53 ~ 80 g/m2 / 14 ~ 22 lb) sideways
paper on the original table.
4. Push SW 101 [B].
5. After the original stops on the exposure glass, gently raise the DJF so
that the original does not move.
6. Confirm that the gap between the trailing edge of the paper and the left
edge [C] of the original rear scale is 10 ± 2 mm.
7. It the gap is not within specification, adjust the registration by using the
Dual Job Feeder

copier SP mode ( 1 SP Adjustment - PAGE 6).

NOTE: 1. Before setting the original on the original table again, open
A376

and close the feed unit cover [C].

2. After completing the adjustment, return the DIP switches to
their original condition.
8. If the registration cannot be adjusted within specifications even though
the SP data is changed to the maximum value, return the data to "00".
9. Adjust the vertical adjustment by turning VR102 on the DJF main board.

FSM 7-29 A095/A096/A097

6.9.3 Combine 2 Originals Mode
1. Make a copy in combine 2 originals mode.
2. Adjust the gap between the first original and the second original. It
should be as small as possible. (Do this by changing the on/off
combination ofDIP SW 102, 3.5mm/step, as shown in the table)
NOTE: Factory settings are all "0" (OFF).
If DIP SW 102-4 is "0" (OFF), the distance between the 1st and
2nd copies is wider (+).
102-4 102-3 102-2 102-1 Shift value
0 0 0 0 0
0 0 0 1 + 3.5 mm
0 0 1 0 + 7.0 mm
0 0 1 1 +10.5 mm
0 1 0 0 +14.0 mm
1 0 0 1 - 3.5 mm
1 0 1 0 - 7.0 mm
1 0 1 1 -10.5 mm
1 1 0 0 -14.0 mm

A095/A096/A097 7-30 FSM

6.10 SIDE TO SIDE REGISTRATION ADJUSTMENT

[D] [A]

[C] [B]

5 ± 2 mm

1. Remove the small cover at the rear side on the upper DJF cover.
2. Turn on DIP SW 101-2 and 101-4.
3. Set a sheet of A4 / 8 1/2" x 11" (53 ~ 80 g/m2 / 14 ~ 22 lb) sideways
paper on the original table.
4. Push SW 101 [A].
5. After the original stops on the exposure glass, gently raise the DJF so
that the original does not move.
6. Confirm that if the gap between the rear edge of the paper and the
original rear scale is 5 ±2 mm.
7. If the gap is not within the specification, adjust the registration by using
copier’s SP mode ( 1 SP Adjustment - PAGE 4).
Dual Job Feeder

8. It the gap is not within specification by using SP mode, loosen the eight
A376

screws fixing the original table [B] and the original guide [C] and shift the
original table and the original guide position accordingly.
NOTE: Before setting the original on the original table again, open and
close the feed unit cover [D].

FSM 7-31 A095/A096/A097

6.11 MOTOR SPEED ADJUSTMENT

DPS101
VR103
VR104
VR105
VR102 VR101

DPS102

SW101 SW102 LED103 LED102 LED101

[B] [C]
[A]

1. Close the DJF and remove the small cover at the rear side on the upper
DJF cover.
2. Turn on DIP-SW No. 101-1, -2 and -4.
3. Turn on the appropriate DIP switch corresponding to the adjusting motor
to be adjusted (see the table below).
4. Rotate the appropriate VR (see the table below) so that LED102 (green)
[A] lights.
NOTE: If the motor rotation speed is too high, LED101 (red) [B] lights
and if too slow, LED 103 (red) [C] lights.
5. Return the DIP switches to their original condition.

Motor DIP SW VR
Feed-in 102-1 103
Belt drive 102-2 104
Feed-out 102-3 105

A095/A096/A097 7-32 FSM

SORTER STAPLER
A377
1. SPECIFICATIONS
Configuration: Console
Number of Bins: 20 + Proof Tray
Paper for Proof Tray:
Size Maximum: A3, 11" x 17"
Minimum: A6 lengthwise, 51/2" x 81/2"
Weight: 52~157 g/m2,14~42 lb
Capacity: 250 sheets (80 g/m2, 20 lb)
Paper for Bins: See the table below.
Sort Stack Staple
Maximum paper size A3, 11" x 17" A3, 11" x 17" A3, 11" x 17"
Minimum paper size A5, 51/2" x 81/2" Sideways: B5, 81/2" x 11"
lengthwise A4, 81/2" x 11"
Lengthwise:
A5, 51/2" x
81/2"
Maximum paper 157 g/m2, 42 lb 157 g/m2, 42 lb 80 g/m2, 20 lb
weight
Minimum paper 52 g/m2, 14 lb 52 g/m2, 14 lb 64 g/m2, 17 lb
weight
Maximum capacity all sizes: all sizes: all sizes:
50 sheets/bin 40 sheets/bin 50 sheets
2 sided copies: 2 sided copies:
40 sheets/bin 35 sheets/bin

a
Staple Position: a = 6 ± 3 mm
b = 6 ± 3 mm
c c = 6 ± 3 mm
d = 66 ± 3 mm
d e = 132 ± 2 mm
θ = 45 ± 5°
e

b
θ
Sorter Stapler
A377

FSM 8-1 A095/A096/A097

Rev. 4/15/94
Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge)
Power Source: DC24V (from copier)
Power Consumption: Average: less than 55W
Maximum:
in sort/stack mode: less than 55W
in staple mode: less than 42W
Dimensions: 566 x 583 x 978 mm
(W x D x H)
Weight: Approximately 47 kg

A095/A096/A097 8-2 FSM

2. COMPONENT LAYOUT
2.1 MECHANICAL COMPONENT LAYOUT

1 2
3

4
14
5
6
13
7
12

11 8

10

1. Proof Tray 8. Sorter Exit Rollers

2. Proof Exit Rollers 9. Staple Unit
3. Proof Transport Rollers 10. Grip Assembly
4. Upper Entrance Guide 11. Helical Wheels
5. Turn Gate 12. Jogger Plate
6. Lower Entrance Guide 13. Bins
7. Sorter Transport Rollers 14. Upper Guide Plate
Sorter Stapler
A377

FSM 8-3 A095/A096/A097

2.2 DRIVE LAYOUT

3
2
4
1
13

5
5
16

15

14

13 6

5 8

9
13
12 9
11
9
10
1. Main Motor 9. Wheel Drive Belts
2. Main Drive Belt 10. Grip Drive Belt
3. Proof Drive Belt 11. Jogger Motor
4. Sorter Drive Belt 12. Staple Unit Drive Motor
5. Helical Wheels 13. Jogger Drive Belts
6. Staple Unit Drive Belt 14. Bin Rear Plate Drive Motor
7. Gripper Motor 15. Sorter Exit Drive Belt
8. Bin Drive Motor 16. Sorter Exit Motor

A095/A096/A097 8-4 FSM

3. ELECTRICAL COMPONENT DESCRIPTION
Please refer to the electrical component layout on the reverse side of the
Point to Point (Water Proof Paper) for symbol and index number.

Index
Symbol Name Function
No.
Motors
1 Main Drives the paper transport rollers. 1
2 Staple Feeds the staples and drives the 10
stapler hammer.
3 Grip Drives the grip assembly forward 16
and backward into the bin to grip
the copies and bring them to the
stapling position.
4 Bin Drive Drives the bins upward and 18
downward by rotating the three
helical wheels.
5 Jogger Drives the jogger plate to jog the 20
copies against the front side
plate.
6 Staple Unit Drive Drives the staple unit according 23
to the staple position and angle.
7 Bin Rear Plate Drive Drives the bin rear plate down 24
and up.
8 Sorter Exit Delivers the paper into the bins. 27
Sensors
1 Bin Jam (LED) Detects if there is paper jams at 3
the distribution section and
detects if there is paper in the
bins (light emitting element).
2 Proof Exit Detects paper jams at the proof 4
tray exit.
3 Entrance Detects paper jams at entrance 5
guides.
4 Staple HP Detects if the staple hammer is in 8
the home position.
Sorter Stapler

5 Staple End Detects staple end. 9

A377

6 Paper Detects whether copies are 11

under the hammer.

FSM 8-5 A095/A096/A097

Index
Symbol Name Function
No.
7 Staple Unit HP Detects if the staple unit is in the 13
home position.
8 Grip HP Detects if the grip assembly is in 15
the home position.
9 Bin Jam (Photo Tr.) Detects paper jams at the 17
distribution section and detects if
there is paper in the bins (light
receiving element).
10 Wheel Sensor Detects the bin position. 19
11 Bin HP Detects if the bins are in the 21
home position.
12 Jogger HP Detects if the jogger plate is in 22
the home position.
13 Bin Rear Plate Open Detects if the bin rear plate is in 25
the open position.
14 Bin Rear Plate HP. Detects if the bin rear plate is in 26
the home (closed) position.
Solenoids
1 Turn Gate Opens and closes the turn gate 2
to direct the copies into either the
proof tray or the bins.
2 Grip Opens and closes the grip arms 12
to grip copies on the bins.
3 Grip Arm Positioning Moves the grip ass’y to the rear 14
and front to catch or release the
paper to carry to the stapler.
PCBs
1 DC Supply Provides DC power (Input: 24V 7
DC, Output:24V/5V DC)
2 Main Control Controls all sorter stapler 28
functions.
Switches
1 Door Safety Cuts the DC power when the 6
front door is opened.

A095/A096/A097 8-6 FSM

4. INSTALLATION
4.1 ACCESSORY CHECK
Check the contents of the box according to the following list.
Description Q’ty
1. Installation Procedure ........................................... 1
2. Front Connecting Bracket ..................................... 1
3. Rear Connecting Bracket ...................................... 1
4. Staple Cartridge .................................................... 1
5. Cushion ................................................................. 1
6. Entrance Guide Mylar ........................................... 1
7. Proof Tray ............................................................. 1
8. Caster Stopper ...................................................... 2
9. Philips Pan Head Screw - M4x12 ......................... 4
10.Philips Screw With Flat Washer - M4x6................. 1
11.New Equipment Condition Report (N.E.C.R.) ........ 1
(-17, -27 machines only)
12.Envelope for N.E.C.R............................................. 1
(-17 machine only)

Sorter Stapler
A377

FSM 8-7 A095/A096/A097

4.2 INSTALLATION PROCEDURE

[B]

[A]

[B]

[A]

[B]

[A]
[B] [A]

[E]

[C]
[D]

CAUTION: Unplug the copier power cord before starting the

following procedure.

1. Remove the strips of tape [A] and the cushions [B].

2. Open the front door and remove the inner cover [C] (3 screws).
3. Remove the strip of tape [D] securing the gripper unit and remove the
cushion [E]. Then re-install the inner cover [C].

A095/A096/A097 8-8 FSM

[A]

[A]

[C]
[B]

[D]

[E]
4. Remove five plastic caps [A] on the copier’s left cover.
5. Install the front connecting bracket [B] (2 screws - M4 x 12) and the rear
connecting bracket [C] (2 screws - M4 x 12) on the copier.
6. Stick the entrance guide mylar [D] on the copier exit area as shown.

NOTE: Align the edge [E] of the cover and the mylar.
Sorter Stapler
A377

FSM 8-9 A095/A096/A097

Rev. 4/4/94

[C]
[D]
[A]

[B]
[H]

[G]
[E]

[F]
[H]

7. Secure the protective earth wire [A]* (1 screw with spring washer) and
the wire [B] (1 screw with spring washer).
NOTE*: For all models other than those intended for North America,
the green wire is intended as a functional ground and
should be connected as shown.
8. Connect the 4P connector [C] and the fiber optic connector [D].
9. Open the front door of the sorter stapler and remove the screw [E] fixing
the locking lever [F], then lower the locking lever.
10. Stick the cushion [G] on the proof tray.
11. Install the entrance guide plate [H] (2 screws - M4 x 6) which is in the
bag on the front door.

A095/A096/A097 8-10 FSM

Rev. 4/4/94

[B]

[A]

[C] [C]

12. Align and press the sorter stapler against the copier and fix them by
raising the locking lever [F].
13. Secure the locking lever [A] (1 screw).
14. Install the proof tray [B].
15. If the gap between the top of the sorter stapler and the copier is too
great, adjust by placing caster stoppers [C].
Sorter Stapler
A377

FSM 8-11 A095/A096/A097

Rev. 4/4/94

[A]

16. Remove the green plastic clip [A] from the staple cartridge, and install
the cartridge in the stapler.
NOTE: When installing the staple cartridge, make sure that all the staple
sheets [B] are in the initial position.

[B]

17. Plug in the copier.

18. Turn on the main switch of the copier and test the operation of the sorter
stapler.
NOTE: The copier automatically recognizes that the sorter stapler has
been installed.

The stapler will not staple for the first 10 or so copies until the
first staple moves to the proper position from the cartridge.

A095/A096/A097 8-12 FSM

5. SERVICE TABLES (MAIN CONTROL BOARD)
5.1 DIP SWITCHES
DIP SW100 0: OFF 1: ON
1 2 3 4 Function
0 0 0 0 Standard setting
1 0 0 0 Raises all bins to the top position.
0 1 0 0 Free run

DIP SW101 DIP SW102

Vertical Staple Horizontal Staple
Position Adjustment Position Adjustment
Adjustment Value 1 2 3 4
Standard Position 0 0 0 –
0.5 mm 1 0 0 0/1
1.0 mm 0 1 0 0/1
1.5 mm 1 1 0 0/1
2.0 mm 0 0 1 0/1
2.5 mm 1 0 1 0/1
3.0 mm 0 1 1 0/1
3.5 mm 1 1 1 0/1
- direction – – – 0
(See the illustration below.)
+ direction – – – 1
(See the illustration below.)
NOTE: The adjustment value and the combination of the dip switch
positions are exactly the same on DIP SW 101 and DIP SW 102.

Feed Feed
direction direction

↑ + direction
↓ – direction
Sorter Stapler

+ direction – direction
A377

FSM 8-13 A095/A096/A097

5.2 TEST POINTS
Number Function
TP100 GND
TP101 +5V

5.3 FUSES
FUSES Connected Point Rated Current and
Voltage
FUSE100 CN100-3 (+24 V) 250 V T5A
FUSE101 CN100-1 (+5 V) 250 V T2A

A095/A096/A097 8-14 FSM

6. REPLACEMENTS AND ADJUSTMENTS
6.1 EXTERIOR COVER REMOVAL
- Front side -
Remove the covers in the order as follows.
[A]

[D]

[B]
[C]

[F]

[E]
1. Remove the proof tray [A] (4 screws).
2. Open the front door.
3. Remove the front inner cover [B] (3 screws).
4. Remove the front wheel cover [C] (3 screws).
5. Remove the four screws fixing the front left cover [D] and remove the
front left cover by shifting the cover up to release the two hooks.
6. Remove the front lower cover [E] (3 screws).
Sorter Stapler

7. Remove the front door [F] (2 hinge pins).

A377

FSM 8-15 A095/A096/A097

- Rear side -

[A]

[B]

1. Remove the rear cover [A] (4 screws).

2. Remove the bottom plate [B] (2 screws and 1 hook).

A095/A096/A097 8-16 FSM

6.2 STAPLER REMOVAL AND REINSTALLATION

[D]

[F] [E]

[A]
[B]

[C]
- Removal -
1. Remove the front inner cover. (Refer to Exterior Cover Removal.)
2. Remove the stapler unit (1 screw [A], 2 connectors).

- Installation -
1. Connect the two connectors [B] and [C].
2. Hook the cut out [D] on the stapler on the stepped screw [E].
3. Install the stapler unit(1 screw).
NOTE: All harnesses should be wired through the cut-out [F] on the
stapler cover. Do not pinch the harness between the cover and
staple unit.
The two connectors must be put inside the stapler cover.
4. Install the front inner cover (3 screws).
Sorter Stapler
A377

FSM 8-17 A095/A096/A097

6.3 JOGGER PLATE REMOVAL AND INSTALLATION

[A]
[B]

[C]

[E]

[D]

- Removal -
1. Remove the proof tray. (Refer to Exterior Cover Removal.)
2. Release the spring [A] of the upper jogger holder [B], then pull out the
jogger plate [C].

- Installation -
1. Insert the jogger plate through the upper holder [B].
2. Push down the jogger plate towards the lower holder [D].
3. Set the jogger plate in the lower holder [D].
4. Hook the spring [A] of the upper jogger holder to the stopper [E].

A095/A096/A097 8-18 FSM

6.4 BINS
[A]
- Removal -

[D]

[C]

[B]

1. Remove the rear cover.

2. Raise all bins to the highest position by turning on DIP SW100-1 on the
sorter main PCB then turn off the main switch of the copier.
3. Remove the jogger plate (refer to Jogger Plate Removal) then move the
upper jogger holder [A] to the front side.
4. Remove the rear cover then remove the bottom plate to access the drive
belt. (Refer to Exterior Cover Removal section.)
5. Manually rotate the helical wheel drive belt [B] and move up the top
guide [C] until the three guide pins [D] reach the top of the helical wheel
as shown.
Sorter Stapler
A377

FSM 8-19 A095/A096/A097

[B] [D]

[A] [C]

[F]
[E]
[H]

[G]
6. Remove the top guide by releasing the pins [A] and [B] from cut-outs [C]
and [D] at the end of the bin guide slots. Then remove the pins [E] and
[F] from cut-outs [G] and [H].
7. Move up the next bin to the top position by manually rotating the helical
wheel drive belt and remove it as in the top guide removal procedure
(step 5 and 6).
8. Remove the other nineteen bins by repeating step.7.

A095/A096/A097 8-20 FSM

- Installation -
[C]
[A]

[F]
[H]
[E]

[B] [G]

[E]
[D]

[J]

[I]

1. While holding the bin rear plate [A] straight, insert rear right guide pin [B]
to the slot [C], then lower the rear guide pin to the corner [D].
2. While still holding the bin rear plate straight, insert the front right guide
pin [E] to guide slot [F].
3. Insert the other guide pins [G] and [H] to the slots [I] and [J].
Sorter Stapler
A377

FSM 8-21 A095/A096/A097

[A]
4. Manually rotate the helical wheel drive belt [A] and lower the bin.
NOTE: Before installing the next bin, rotate the helical wheels only once.
Otherwise, the distance between the guide pins [B] become
uneven and the bin tilts

[B]

Good No good
5. Set all bins and the top cover by repeating steps 1 to 4.
6. Re-install the jogger plate and all covers.

A095/A096/A097 8-22 FSM

6.5 MAIN MOTOR REMOVAL

[A]

[E]
[B]

[F]

[D]
[C]

1. Remove the rear cover (4 screws).

2. Disconnect the connector [A].
3. Remove the main motor bracket [B] (4 screws) with the main motor.
4. Remove all gears and pulleys [C] [D] [E] [F] (3 E-rings).
5. Remove the main motor (4 screws).
Sorter Stapler
A377

FSM 8-23 A095/A096/A097

6.6 GRIP ASSEMBLY REMOVAL, AND GRIP SOLENOID
AND GRIP POSITIONING SOLENOID ADJUSTMENT

[A] [B]

[B]

[C] [D]

[C]

[D]

- Grip assembly removal -

1. Open the front cover then remove the front inner cover. (Refer to Exterior
Cover Removal.)
2. Remove the grip assembly [A] (4 connectors, 3 screws).
3. Replace the grip solenoid [B] and the grip arm positioning solenoid [C].

- Grip solenoid [B] and the grip arm positioning solenoid [C]
adjustments -
It is impossible to perform the fine positioning adjustments for both solenoids
because magnets in both solenoids pull the plunger very strongly.
So, mark the original position of each solenoid and remove it. Then place the
solenoid at the original position by referring to the mark you made [D] and
tighten the screws (4 screws for the grip solenoid and 3 screws for the grip
arm positioning solenoid).

A095/A096/A097 8-24 FSM

6.7 MAIN CONTROL BOARD REPLACEMENT

[A]

1. Remove the rear cover (refer to Exterior Cover Removal) then

disconnect all connectors (15 connectors and 1 fiber optics connector).
2. Remove the main control board [A] (6 studs).
3. Install the new main control board and set all connectors.
4. Position DIP SW101 and 102 as on the original main control board (DIP
SW 101 and 102 are for staple position adjustment).
5. Turn on the copier main switch then confirm the staple position. If
incorrect, adjust the staple position. (Refer to the Staple Position
Adjustment.)

Sorter Stapler
A377

FSM 8-25 A095/A096/A097

6.8 STAPLE POSITION ADJUSTMENT
ADJUSTMENT STANDARD:
a~c : 6 ± 3 mm
a
b : 6 ± 3 mm
c : 6 ± 3 mm
c d : 66 ± 3 mm
e : 132 ± 2 mm
d θ : 45 ± 5 [A]
e
[B]

b
θ

[C]
ADJUSTMENT
Both the vertical and the horizontal staple positions are adjustable as follows:
1. Enter SP mode as follows:
a. Press the clear modes key.
b. Enter 107.
c. Press and hold the clear/stop key for three seconds.

2. Touch the "SP Adjustment" key.

3. Touch the Prev. key [A] four times to access page 12.
4. Adjust the vertical staple position by touching the , keys [B]
and the horizontal staple position by touching the , keys [C].
NOTE: 0.5mm/step

A095/A096/A097 8-26 FSM

6.9 HELICAL WHEELS
- Removal -
Before removing the helical wheels, remove all bins and all exterior covers.
(Refer to Exterior Cover and Bins Removal.)

- Front Helical wheel -

[A]
[F]

[B]

[C]

[C]
[D]
[E] [D]

1. Remove the bracket [A] (4 screws).

2. Remove the wheel sensor bracket [B] (1 screw).
3. Unhook the two springs [C].
4. Loosen the two Allen screws [D].
5. While holding the pulley [E] to keep it in position, remove the helical
wheel [F].
Sorter Stapler
A377

FSM 8-27 A095/A096/A097

- Rear Long Helical Wheel -

[A]

[E]
[B]
[F]

[D]

[E] [D]
[C]
1. Remove the bracket [A] (3 screws).
2. Unhook the spring [B] at the front side and the spring [C] at the rear side.
3. Loosen the two Allen screws [D] on the drive pulley.
4. While holding the pulley [E] to keep it in position, remove the helical
wheel [F].

A095/A096/A097 8-28 FSM

- Rear Short Helical Wheel -
[A]

[E]
[D] [B]

[C]
[D]

1. Remove the bracket [A] (3 screws).

2. Loosen the screw [B] then unhook the tension spring [C].
3. Loosen the two Allen screws [D] on the drive pulley.
4. Remove the helical wheel [E].
Sorter Stapler
A377

FSM 8-29 A095/A096/A097

- Installation -
NOTE: After installing the helical wheels, perform the helical wheels
alignment which is explained later.
- Rear Short Helical Wheel -

[D]
[F] [E]
[F]
[K]

[J]

[G]

[A] [H]
[B] [C]

[I]

1. Place the bearing [A] on the notch [B] on the bottom plate then set the
timing belt-426XL [C] around the pulley.
2. Set the helical wheel [D] into the pulley [E]. Leave the Allen screws [F]
loosened.
3. Set the helical wheel [D] with the pulley [E] on the bearing [A].
4. Set the bracket with the bushing [G] on top of the helical wheel then
install and slightly tighten the three screws [H].
5. Place a 0.4mm thickness gauge [I] between the helical wheel and the
bushing [G] on the bracket. While holding the bushing down to the helical
wheel, tighten the three screws [H].
6. Set the tension spring [J], then tighten screw [K].

A095/A096/A097 8-30 FSM

- Rear Long Helical Wheel -
[L] [C] [E]

[A]

[J] [I]

[F] [G]
[D]
[B]
[K]

0.4 mm

[E]

[H]

1. Place the bearing [A] on the notch on the bottom plate then set timing
belt-426XL [B] and timing belt-918XL [C] around the pulley [D].
2. Set the helical wheel [E] into the pulley [D] then set the helical wheel on
the bushing [A].
3. Set the bracket with the bushing [F] on top of the helical wheel then
install and slightly tighten three screws [G].
4. Place a 0.4 mm thickness gauge [H] between the helical wheel [E] and
the bushing [F] on the bracket. While holding the bushing down to the
helical wheel, tighten the three screws [G].
5. Hook tension springs [I] and [J], then tighten screws [K] and [L].
Sorter Stapler
A377

FSM 8-31 A095/A096/A097

- Front Helical Wheel - [J]
[K]
[K]

[F]
[G]
[H]

[O]
[H]
[L]

[C]
[E]
[B]
[D] [A]

[N]
[M]
[I]
[P] [I]

1. Place the bearing [A] on the notch [B] on the bottom plate then set timing
belt-918XL [C] and timing belt-300XL [D] around the pulley.
2. Set the pulley [E] on the bearing. The direction of the pulley should be as
shown in the illustration.
3. Slide the wheel sensor actuator [F] onto the helical wheel. Leave the
Allen screw [G] loosened.
4. Set the helical wheel [H] in the pulley [E]. Leave the Allen screws [I]
loosened.
5. Set the bracket with a bushing [J] on top of the helical wheels then install
and slightly tighten the four screws [K].
6. Place a 0.4 mm thickness gauge [L] between the helical wheel and the
bushing on the bracket. While holding the bushing down to the helical
wheel [H], tighten the four screws [K].
7. Hook tension springs [M] and [N] then tighten the screw [O].
8. Install the wheel sensor bracket [P].

A095/A096/A097 8-32 FSM

- Alignment of the 3 Helical Wheels -
[B]
[A]

[A]
[D]
[E]

[C]

[C]

[C]

1. Confirm all belts are set correctly.

2. Align all holes [A] at the middle of the helical wheels at the center of the
bin guide slots [B], as shown.
3. In this condition, tighten all Allen screws [C] on the helical wheel drive
pulleys (2 Allen screws on each drive pulley).
4. In this condition, place the cut out [D] on the wheel sensor actuator under
the wheel sensor [E] then tighten the Allen screw on the wheel sensor
actuator.
Sorter Stapler
A377

FSM 8-33 A095/A096/A097

RECIRCULATING DOCUMENT
HANDLER
A378
1. SPECIFICATIONS
Original Size: Max A3, 11" x 17"

Recirculating
Min A5 lengthwise, 5 1/2" x 8 1/2"

Document
Handler
(No A5 Sideways, 8 1/2 x 5 1/2)

A378
Original Weight: 52~104 g/m2 (14~28 lb) (ARF)
52~128 g/m2 (14~34 lb) (ADF)
Original Feed Mode: Automatic Feed (ADF)
Automatic Recycle Feed (ARF)
Original Capacity: Max 50 sheets (A4, 8 1/2" x 11")
Original Separation: Feed and Friction Belts system
Original Transport: One flat belt
Original Stop System: DC servo motor control system
Copying Speed: Continuous copy
55 cpm (A4S, 11" x 81/2", 1st feed station)
Single copy
55 cpm (A4S, 11" x 8 1/2", 1st feed station)
Number of Cycles Max 30 times
per Document:
Power Source: 24V (from copier), 5 A
Power Consumption: 70W
Dimensions: 645 x 516 x 132 millimeters
(W x D x H) (25.4 x 20.4 x 5.2 inches)
Weight: Approximately 18 kg (39.7 lb)

FSM 9-1 A095/A096/A097

2. MECHANICAL COMPONENT LAYOUT

1 2 34 5 6 7 8 9 10

13 12 11

1. Friction Belts 8. Exit Relay Belts

2. Feed Roller 9. Inverter Pawls
3. Original Gate 10. Inverter Roller
4. Pick-up Rollers 11. Transport Belt
5. Original Stacker 12. Pull-out Roller
6. Push-plate 13. Pulse Generator
7. Feed-out Rollers

A095/A096/A097 9-2 FSM

3. ELECTRICAL COMPONENT DESCRIPTIONS
Please refer to the electrical component layout on the reverse side of th

Recirculating
Point to Point (waterproof paper) for symbol and index number.

Document
Handler
A378
Index
Symbol Name Function
No.
Motors
M1 Feed-in Motor Drives the feed-in system
(pick-up rollers, feed roller, and 3
pull-out roller). (dc servo)
M2 Transport Belt Motor Drives the transport belt. (dc
4
servo)
M3 Inverter Motor Drives the inverter roller and the
9
exit relay belts.
M4 Feed-out Motor Drives the feed-out unit. 15
M5 Friction Belt Motor Drives the friction belts 21

Solenoids
SOL1 Original Gate Energizes to open the original
22
Solenoid gate.
SOL2 Inverter Solenoid Energizes to invert the original
when copying a two-sided 8
original.
SOL3 Push Plate Solenoid Energizes to push the stack of
14
originals to the feed-in section.

Switches
SW1 Lift Switch Informs the copier CPU when the
RDH is lifted and also serves as 7
the jam reset switch for the RDH.
SW2 Feed-in Unit Safety Detects if the feed-in unit is set
23
Switch correctly.
SW3 Feed-out Unit Safety Detects if the feed-out unit is set
10
Switch correctly.

FSM 9-3 A095/A096/A097

Index
Symbol Name Function
No.
Sensors
S1 Original Set Sensor Informs the copier CPU that
originals have been placed and
17
causes the Insert Original
indicator to go out.
S2 Recycle Sensor Informs the CPU when the top
original is fed from the original 19
stacker.
S3 Registration Sensor Sets original stop timing and
18
measures the original’s length.
S4 Original Width Determines the width of the
20
Sensor original.
S5 Pulse Generator Generates the pulses used to
1
Sensor measure the original’s length.
S6 Inverter Sensor Sets original stop timing when in
11
auto reverse mode.
S7 Feed-out Sensor Checks for original misfeeds. 13
S8 One Turn Sensor Informs the CPU when the
6
pick-up roller turns one rotation.
S9 RDH Position Sensor Informs the CPU when the RDH
is being closed so that APS
16
sensor can begin checking the
original size.

Magnetic Clutch +
CL1 Feed-in clutch Energizes to rotate the feed
2
roller.

Printed Circuit Boards

PCB1 RDH Main PCB Controls all RDH functions. 12
PCB2 Indicator Panel PCB Contains indicators for the
5
operator.

A095/A096/A097 9-4 FSM

4. INSTALLATION
4.1 ACCESSORY CHECK

Recirculating
Document
Check the accessories in the box according to the following list:

Handler
A378
Description Q’ty
1. Installation Procedure .............................................................1
2. RDH Test Chart.......................................................................1
3. Switch Actuator .......................................................................1
4. Hinge Stopper .........................................................................2
5. Shoulder Screw (-) – M5 .........................................................2
6. Shoulder Screw (+) – M5 ........................................................2
7. Shoulder Screw – M4..............................................................2
8. Philips Pan Head Screw – M4 x 6...........................................2
9. NECR (for -17, -27 machines only).........................................1
10. Envelope - NECR (for -17 machine only)................................1

FSM 9-5 A095/A096/A097

4.2 INSTALLATION PROCEDURE

[A]
[A]

[B]

[A]

[C]

CAUTION: When installing the Recirculating Document Handler

(RDH), make sure that the copier is unplugged.

1. Remove the tape strips [A] and the cushion [B] clamping the belt unit.
2. Remove the sensor [C] from the copier (1 screw).
NOTE: Sensor [C] is not installed to the copier when it is packed in its
box.
Sensor [C] is an accessory of the platen cover (option).

A095/A096/A097 9-6 FSM

[A]
[B]
[B]

Recirculating
Document
Handler
A378
[C]

[E]

[D]

3. Install the cover [A] with a screw supplied as an accessory of the copier.
4. Install four stepped screws (front: M4, rear: M5 minus screw) [B] to hook
the RDH.
NOTE: There is one screw hole available on the left side for one of the
stepped screws. However there are two screw holes available
on the right where the stepped screw is to be installed.
Install the stepped screw into the outer screw hole [C] as shown
in the illustration.
5. Mount the RDH to the two stepped screws [D] by aligning the holes in
the RDH hinge [E] and the stepped screws, then slide the RDH to the
right as shown.

FSM 9-7 A095/A096/A097

[A]

[B]

[C]

[D]

[E]

6. Secure the RDH to the copier with two plus (M5) stepped screws [A].
7. Remove a small cap on the upper rear cover of the copier then connect
the connector [B] and the fiber optic cable connector [C].

CAUTION: Place the fiber optic cable [C] over the electrical cable [B]
so as not to bend the fiber optic cable [C] while opening
and closing the RDH.

8. Install the switch actuator [D] (1 screw).

9. Close the RDH then install the two angle stoppers [E].
10. Plug in the copier and turn on the main switch.
NOTE: The copier automatically recognizes that the RDH has been
installed.
11. Make copies using the RDH and confirm the copy image.

A095/A096/A097 9-8 FSM

5. SERVICE TABLE
5.1 TEST POINT TABLE

Recirculating
Document
Handler
Number Function

A378
TP1 GND

5.2 FUSE TABLE (Main Board)

Number Rated Current
F1 5A

5.3 LED TABLE

LED No. ON Status
LED 1 Motor speed is too high.
LED 2 Motor speed is normal
LED 3 Motor speed is low
NOTE: While each motor is adjusted, if the motor speed is normal LED
2 lights, if the motor speed is too high LED 1 lights, if the motor
speed is too low LED 3 lights.

FSM 9-9 A095/A096/A097

5.4 DIP SWITCH TABLE
Factory Setting

DIP SW 2 DIP SW 1
1 2 3 4 1 2 3 4
0 0 0 0 0 0 0 0
After performing the following tests, these DIP switches should be returned
to the factory settings.

Motor Test

DIP SW 2 DIP SW 1
Description Note
1 2 3 4 1 2 3 4
1 0 0 0 Feed-in Motor 1
1 1 0 1 0 1 0 0 Transport Belt Motor
0 0 1 0 Inverter Motor
0 0 0 1 Feed-out Motor 2
Note 1: When these DIP SW combinations are set. The motors start
rotating. While SW 3 is held down. The motor rotates in the reverse
direction.
Note 2: When these DIP SW combinations are set, the motors start rotating.
While SW 3 is held down, the motor rotates slowly.

Paper Feed

DIP SW 2 DIP SW 1
Description
1 2 3 4 1 2 3 4
Feeds a sheet of paper
0 0 0 0
(Scale Registration)
0 1 0 1
Feeds a sheet of paper
0 1 0 0
(Timing Registration)
Note: With these DIP SW combinations, press SW 3 to feed a sheet of
paper. Press SW 3 again to reverse the paper feed direction, then
press SW 3 to feed out the sheet.

A095/A096/A097 9-10 FSM

Clutch and Solenoid Test

DIP SW 2 DIP SW 1
Description

Recirculating
1 2 3 4 1 2 3 4

Document
Handler
A378
1 0 0 0 Push Plate Solenoid
0 0 1 1 0 1 0 0 Feed-in Clutch
0 0 1 0 Inverter Solenoid
0 0 0 1 Original Gate Solenoid
Note: Press SW 3 to energize the clutches and solenoids.
Free Run Mode (With paper)

DIP SW 2 DIP SW 1
Description Note
1 2 3 4 1 2 3 4
0 0 0 0 Single Operation
(Scale Registration,
Single Side)
1 0 0 0 Single Operation
(Scale Registration, 1
Double Side)
1 0 0 1 0 1 0 0 Single Operation
(Timing
Registration, Single
Side)
* * 0 1 Repeat Operation
(Up to 30 sets)
2
* * 1 1 Repeat Operation
(Limitless)
Note 1: With these DIP SW combinations, press SW 3 to start feeding
sheets from a paper stack in and out. Each sheet is fed once.
Note 2: With these DIP SW combinations, press SW 3 to feed paper in and
out continuously. (The same stack of sheets is fed in and out
repeatedly.)

Free Run (Without paper)

DIP SW 2 DIP SW 1
Description
1 2 3 4 1 2 3 4
1 1 1 0 0 0 0 0 Free Run
Note: With this DIP SW combination, press SW 3 to start RDH operation
without paper. Press SW 3 again to stop.

* Not Applicable

FSM 9-11 A095/A096/A097

6. REPLACEMENTS AND ADJUSTMENTS
6.1 TRANSPORT BELT REPLACEMENT

[E]

[A]

[D]

[C]

[B]

1. Turn off the copier main switch and lift the RDH unit.
2. Open the transport belt unit [A] (2 screws).
3. Slide the belt tension plate [B] to the left (1 screw), then lower
the belt tension unit [C].
4. Replace the transport belt.
NOTE: The RDH belt has to be installed in the notch as shown [D].
The feed out unit [E] has to be opened when the transport belt
unit is reinstalled.

A095/A096/A097 9-12 FSM

6.2 PAPER FEED ROLLER REMOVAL

[E]

Recirculating
Document
Handler
A378
[B]
[C]
[D] [a]

[a]

[A] [a]

[H]
[F]

[I]
[G]

1. Turn off the copier main switch, then remove the RDH front cover [A]
(remove 2 screws, loosen 3 screws [a]) and the lower rear cover [B] (2
screws).
2. Remove the rear cover [C] (4screws).
3. Open the feed-in unit [D].
4. Remove the feed-in unit cover [E] (4 screws) and the paper guide mylar
[F] (2 screws).
5. Loosen the feed-in unit release button holder pins [G], then slide the
holder to the front and remove the paper feed guide plate [H] (2 screws).
6. Remove the paper feed roller [I] (3 E-rings, 1 bearing, 2 pins, and 2
pull-out rollers).
NOTE: Be careful not to lose the pins.

FSM 9-13 A095/A096/A097

6.3 FRICTION BELT REPLACEMENT

[B]
[A]

[C]

1. Turn off the copier main switch, then open the paper feed unit [A].
2. Remove the paper guide plate [B] (2 screws).
3. Replace the 3 friction belts [C] (1 E-ring and 1 busing).

A095/A096/A097 9-14 FSM

6.4 PAPER EXIT TRANSPORT BELT REMOVAL
[E]

Recirculating
Document
Handler
A378
[C]

[A]
[D]

[B]

[H]
[G]
[F]

1. Turn off the copier main switch.

2. Remove the lower rear cover [A], rear cover [B] and the right side cover
[C] (2 screws).
3. Remove the inverter solenoid bracket [D] (2 screws).
4. Slide the paper exit unit all the way to the left.
5. Remove the 2 screws for the transport unit [E] , and open the exit unit.
Then remove the other 2 screws [F].
6. Carefully lift the front end of the transport unit [G], then remove the 4
paper exit transport belts [H].
NOTE: Reinstall the inverter solenoid bracket after sliding the paper exit
unit all the way to the right.

FSM 9-15 A095/A096/A097

6.5 RDH MAIN CONTROL BOARD REMOVAL

[B]
[A]

[C]

[D]

1. Turn off the copier main switch, then remove the rear cover.
2. Disconnect all connectors for the main control board and for the flexible
cable (8 connectors, 1 optics cable, 1 harness clamp).
3. Remove the LED bracket [A] (1 screw) and the flexible cable [B]
(2 screws).
4. Remove the main board cover [C] (2 screws).
5. Remove the main control board [D].
NOTE: After replacing the main control board, perform the leading edge
registration and the motor speed adjustments.

A095/A096/A097 9-16 FSM

6.6 RDH LEADING EDGE REGISTRATION ADJUSTMENT

Recirculating
Document
Handler
A378
NOTE: Before confirming the original registration, make sure that the main
frame registration is within specifications.

1. Confirm the original front side registration as follows:

1) Make a copy of the test chart in platen mode (A4/81/2" x 11",
sideways).
2) Make a copy of the test chart in RDH mode.
3) Compare the registration of the copy in platen mode with that in RDH
mode, and confirm that there is no more than a 1.0 mm difference.
4) If the difference is more than 1.0 mm, adjust the registration by using
the copier’s SP mode ( 1 SP Adjustment – PAGE 6).
5) Install the RDH rear cover.

FSM 9-17 A095/A096/A097

[A]

[B]

2. Confirm the original reverse side registration as follows:

1) Make a copy of the test chart’s 2nd side in platen mode (A4/81/2" x
11", sideways).
2) Make a copy of the test chart in RDH 2-sided mode.
3) Compare the registration of the copy in platen mode with that in RDH
2-sided mode, and confirm that there is no more than a 2.0 mm
difference.
4) If the difference is more than 2.0 mm, remove the left scale [A] (2
screws), then set a sheet of A4/81/2" x 11" sideways paper [B] on the
exposure glass edge as shown.

NOTE: Without the left scale, the original jams when it strikes the
exposure glass edge. This sheet of paper prevents that.
5) Set DIP SW 1 and 2 on the main PCB as follows:

DIP SW 2 DIP SW 1
1 2 3 4 1 2 3 4
0 1 0 1 0 1 0 0

A095/A096/A097 9-18 FSM

[D]

Recirculating
Document
Handler
A378
10.0 ± 2..0 mm

[C]

6) Set a test chart on the RDH, then press SW 3 to feed the test chart
through the RDH.
7) When the test chart stops on the exposure glass, gently pull off the
sheet of paper set in step 4), then press SW 3 again to feed the test
chart in the reverse direction.
8) Open the RDH slowly so that the test chart [C] does not move from the
stop position.
9) Confirm that the test chart has stopped at the correct position, 10 ± 2.0
mm from the scale edge (0 position) [D].
10) If the test chart did not stop at the correct position, adjust the
registration by using the copier’s SP mode ( 1 SP Adjustment –
PAGE 6).

3. Turn all DIP SW’s off and turn off the main switch, then reassemble the
machine.
4. Check the operation of the RDH.

FSM 9-19 A095/A096/A097

6.7 MOTOR SPEED CHECK & ADJUSTMENT

1. Remove the RDH rear cover (4 screws), and set DIP SW 1 and 2
as follows:

DIP SW
DIP SW
DPS 2 DPS 1 Combination
Description
1 2 3 4 1 2 3 4
1 0 0 0 Feed-in Motor 1
Transport Belt
1 1 0 1 0 1 0 0 2
Motor
0 0 1 0 Inverter Motor 3
0 0 0 1 Feed-out Motor 4

A095/A096/A097 9-20 FSM

Rev. 4/15/94

Recirculating
Document
Handler
A378
2. Close the RDH.
NOTE: For the DIP SW combinations, refer to the table on the previous
page.
3. Set DIP SW 1 combination #1. The paper feed motor starts turning. Turn
VR 3 until LED 2 lights.
4. Set DIP SW 1 combination #1. The paper feed motor reverses direction
while SW 3 is pressed (ON). Turn VR 2 until LED 2 lights.
5. Set DIP SW 1 combination #2. The transport belt motor starts. Turn VR 1
until LED 2 lights.
6. Set DIP SW 1 combination #3. The inverter motor starts turning. Turn
VR 4 until LED 2 lights.
7. Set DIP SW 1 combination #4. The feed-out motor starts turning. Turn
VR 5 until LED 2 lights.
8. Check the operation of the RDH.
9. Turn all DIP SW’s off.
10. Reassemble the machine.

FSM 9-21 A095/A096/A097

FINISHER
A379
Rev. 4/15/94
1. OVERALL MACHINE INFORMATION
1.1 SPECIFICATIONS
Paper Size: Maximum: 11" x 17"/A3
Minimum: 51/2" x 81/2"/A6 Lengthwise
Paper Weight: Standard copying/Stack mode
14 ~ 42 lb/52 ~ 157 g/m2
Staple mode
17 ~ 20 lb/64 ~ 80 g/m2

Finisher
A379
Paper Capacity: 1,500 sheets:
81/2" x 11"/A4 (20 lb/80 g/m2)
1,000 sheets:
81/2" x 14"/B4 or larger size (20 lb/80 g/m2)
Stapler Capacity: 81/2" x 11"/A4 or smaller size (20 lb/80 g/m2):
from 2 to 50 sheets
81/2" x 14"/B4 or large size (20 lb/80 g/m2):
from 2 to 30 sheets
Staple Replenishment: Cartridge exchange (5,000 pieces/cartridge)
Power Source: DC 24 V (from copier)
Power Consumption: 44.4 W (average)
Weight: 35 kg (77.2 lb)

FSM 10-1 A095/A096/A097

Rev. 4/15/94
Stapling Position:

(1 staple) (2 staples)

a = 0.24" ± 0.12" (6 ± 3 mm) a = 0.24" ± 0.12" (6 ± 3 mm) a = 0.24" ± 0.12" (6 ± 3 mm)

b = 0.24" ± 0.12" (6 ± 3 mm) b = 0.24" ± 0.12" (6 ± 3 mm) b = 5.20" ± 0.08" (13.2 ± 2 mm)

Dimensions: 26.4" x 20.2" x 37.4"

(671 mm x 514 mm x 950 mm)

A095/A096/A097 10-2 FSM

Rev. 4/4/94
1.2 MECHANICAL COMPONENT LAYOUT

2 1 13 12

11

Finisher
A379
4
10

9
5

8
7

1. Stack Height Sensor Feeler 8. Alignment Brush Roller

2. Shift Tray 9. Lower Transport Rollers
3. Shift Tray Positioning Roller 10. Entrance Rollers
4. Jogger Unit 11. Junction Gate
5. Positioning Roller 12. Upper Transport Rollers
6. Stack Feed-out Belt 13. Exit Rollers
7. Stapler Unit

FSM 10-3 A095/A096/A097

1.3 ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the Point to
Point (water proof paper) index numbers.

Index
Symbol Name Function
No.
Motors
M1 Transport Drive Drives transport rollers. 23
M2 Shift Tray Lift Moves the shift tray up or down. 24
M3 Exit Drive Drives the exit and shift tray
22
positioning rollers.
M4 Stack Feed-out Drives the stack feed-out belt. 5
M5 Jogger Moves the jogger fences. 17
M6 Stapler Drive Moves the stapler unit. 14
M7 Shift Moves the shift tray side to side. 8
M8 Staple Drives the staple hammer. 12

Sensors
S1 Entrance Detects copy paper entering into
25
the finisher.
S2 Jogger Unit Entrance Detects copy paper entering into
18
the jogger unit.
S3 Jogger Unit Paper Detects copy paper in the jogger
6
unit.
S4 Stack Feed-out Belt Detects the home position of the
15
HP stack feed-out belt.
S5 Jogger HP Detects the jogger home position. 16
S6 Exit Detects misfeeds in exit area. 3
S7 Stack Height 1 Detects copy paper stack height
2
in staple mode.
S8 Stack Height 2 Detects copy paper stack height
1
in sort/stack mode.
S9 Shift Tray Lower Limit Detects the lower limit of the shift
tray position. 13

S10 Stapler Hammer HP Detects the staple hammer home

position. 11

A095/A096/A097 10-4 FSM

Index
Symbol Name Function
No.
S11 Shift Tray Half-Turn Detects shift tray side-to-side
7
position.
S12 Stapler Unit HP Detects the stapler unit home
9
position.
S13 Staple End Detects staples in the cartridge 10
Switches

Finisher
A379
SW1 Front Door Safety Cuts dc power when the front
26
(Switch) door is opened.
SW2 Shift Tray Upper Detects the upper limit of the shift
4
Limit (Switch) tray position.

Solenoids
SOL1 Positioning Roller Lowers the positioning roller in
19
the jogger unit.
SOL2 Junction Gate Drives the junction gate. 21

PCBs
PCB1 Main Control Controls overall finisher operation. 20

FSM 10-5 A095/A096/A097

1.4 DRIVE LAYOUT 4 3 2 1

10

5
9

12 11 7 8

16

15

13 14

1. Exit Drive Motor 9. Shift Cam

2. Upper Transport Drive Belt 10. Exit Roller
3. Shift Tray Lift Motor 11. Stack Feed-out Motor
4. Transport Drive Motor 12. Jogger Motor
5. Transport Drive Belt 13. Stapler Drive Motor
6. Lower Transport Drive Belt 14. Stapler Drive Belt
7. Shift Tray Lift Belt 15. Jogger Drive Belt
8. Shift Motor 16. Stack Feed-out Belt

A095/A096/A097 10-6 FSM

2. INSTALLATION
2.1 ACCESSORY CHECK
Check the accessories in the box according to the following list.
Description Q’ty
1. Installation Procedure .............................................................1
2. Front Connecting Bracket .......................................................1

Finisher
3. Rear Connecting Bracket ........................................................1

A379
4. Staple Cartridge ......................................................................1
5. Entrance Guide .......................................................................1
6. Shift Tray .................................................................................1
7. NECR (for -17 machine only) ..................................................1
8. Cushion – 5 x 10 x 345 ...........................................................1
9. Cushion – 5 x 10 x 125 ...........................................................1
10. Cushion – 5 x 10 x 637 ...........................................................1
11. Philips Truss Head Screw – M4 x 8 ........................................4
12. Philips Pan Head Screw – M4 x 12.........................................4
13. Philips Screw with Flat Washer – M4 x 8................................2
14. Envelope – NECR (for -17 machine only)...............................1

FSM 10-7 A095/A096/A097

2.2 INSTALLATION PROCEDURE

[C]
[F]
[B]
[D]

[A]

[A] [E]

[C]

[G]

CAUTION: Unplug the copier power cord before starting the

following procedure.

1. Remove the strips of tape [A] and the cushion [B].

2. Open the front door and remove the strips of tape [C] and cushion [D].
3. Remove the clamp [E] (1 screw).
4. Slide out the staple unit [F].
5. Remove the strip of tape [G].

A095/A096/A097 10-8 FSM

Finisher
A379
[C]
[B]
[A]

[D]

[D] [E]

6. Remove five plastic caps [A] on the copier’s left cover.

7. Install the front connecting bracket [B] (2 screws– M4 x 12) and the rear
connecting bracket [C] (2 screws– M4 x 12) on the copier.
8. Stick the entrance guide mylar [D] on the copier exit area as shown.
NOTE: Align the edge [E] of the cover and the mylar.

FSM 10-9 A095/A096/A097

Rev. 4/15/94

[C]

[D]
[J]
[A]
[G]

[B]

[H]
[L]
[E]
[F]
[I]

[K]
9. Secure the protective earth wire [A]* (1 screw with spring washer) and
the wire [B] (1 screw with spring washer).
*NOTE: For all models other than those intended for North America, the
green wire is intended as a functional earth ground and should
be connected as shown.
10. Connect the 4P connector [C] and the fiber optic connector [D].
11. Open the front door of the finisher and remove the screw [E] fixing the
locking lever [F], then lower the locking lever.
12. Stick the cushions [G] (middle), [H] (short), [I] (long) as shown.
NOTE: Stick the cushion [G] on the metal stay (not on the cover).
Align the upper edge of the cushion [H] with the edge of the stay
[J].
Align the lower edge of the cushion [I] with the edge of the
stay [K].
13. Install the entrance guide plate [L] (2 screws - M4x6).

A095/A096/A097 10-10 FSM

Rev. 4/15/94

[G]
[D]

[C]

Finisher
A379
[E] [B]

[A]

[F]

14. Align and press the finisher against the copier and fix them by raising the
locking lever [A].
NOTE: At this time, confirm that the mylar [B] is located between the
guides [C].
15. Secure the locking lever [A] (1 screw).
16. Install the shift tray [D] with 4 screws – M4 x 8 (remove tape [E]).
17. Adjust the height of the copier by using the leveling foot [F] so that the
difference in level between the copier and the finisher will be
30 ± 1 mm.

FSM 10-11 A095/A096/A097

Rev. 4/15/94

[B]
[A]

18. Remove the green plastic clip [A] from the staple cartridge, and install
the cartridge in the stapler.
NOTE: When installing the staple cartridge, make sure that all the staple
sheets [B] are in the initial position.
19. Plug in the copier.
20. Turn on the main switch of the copier and test the operation of the
finisher.
NOTE: The copier recognizes automatically that the finisher is installed.

The stapler will not be stapling for the first 10 or so copies until the first
staple comes to the proper position.

A095/A096/A097 10-12 FSM

3. SERVICE TABLES
3.1 TEST POINT TABLE (Main Board)
Number Function
TP3 GND

3.2 FUSE TABLE

Finisher
A379
Number Rated Current Location
Fuse 1 5A Main PCB

3.3 LED TABLE

LED No. ON Status
LED1 Motor speed is too high.*
LED3 Motor speed is too low.*
*NOTE: While each motor is adjusted, if the motor speed is normal, LED
1 and LED 3 light. If the motor speed is too high, only LED 1
lights. If the motor speed is too low, only LED 3 lights.
There is no LED 2.

FSM 10-13 A095/A096/A097

3.4 DIP SW TABLE
3.4.1 Factory Setting

DIP SW101 DIP SW102

1 2 3 4 1 2 3 4
0 0 0 0 0 0 0 0

3.4.2 Motor Test Mode

DIP SW101 DIP SW102

Motor
1 2 3 4 1 2 3 4
1 1 0 1 1 0 0 0 Stack Feed-out Motor
After setting DIP SW101, turn on switch 1 of DIP SW102 to start
the stack feed-out motor, turn off the DIP SW102 to stop the motor.

3.4.3 Free Run Test Mode Without Paper

DIP SW101 DIP SW102

Function
1 2 3 4 1 2 3 4
1 1 1 0 1 0 0 0 Shift Tray Mode
1 1 1 0 0 1 0 0 Staple mode - (1)
1 1 1 0 0 0 1 0 Staple mode - (2)
1 1 1 0 0 0 0 1 Staple mode - (3)
Free run test mode starts when SW101 on the main board is
pressed, and stops when SW102 is pressed.

If in shift tray mode, the finisher works as if 3 sets of 5 LT sized pages

are being sorted. The shift tray is lowered for each of the 3 sets and then
returns to its home position to repeat the same operation.
If in staple mode, the finisher works as if 3 sets of 5 LT sized pages are
being stapled and delivered. The machine is then initialized and repeats the
same operation.

A095/A096/A097 10-14 FSM

3.4.4 Off Line Test Mode

DIP SW101 DIP SW102

Mode
1 2 3 4 1 2 Copy Q’ty 3 4 Paper Size
A4
1 1 0 0 Shift Tray Mode 0 0 2 sheets 0 0
Sideways
Staple Mode A4 Length-
1 0 0 1 1 0 10 sheets 1 0
(1) wise
Staple Mode LT

Finisher
0 1 1 0 0 1 30 sheets 0 1

A379
(2) Sideways
Staple Mode LT Length-
0 1 0 1 1 1 50 sheets 1 1
(3) wise
Off line test mode starts when SW101 on the main board is pressed, and
stops when SW102 is pressed.
The operation of the finisher can be checked without the main copier.

FSM 10-15 A095/A096/A097

4. REPLACEMENTS AND ADJUSTMENTS
4.1 EXTERIOR REMOVAL
[G]
[A] [B]

[C]

[D]
[H]

[I]

[J] [E]
[I] [F]
1. Remove the left upper cover [A] (2 screws).
2. Remove the upper cover [B] (3 screws).
3. Remove the upper door bracket [C] (1 screw) and remove the front door
[D].
4. Remove the lower front cover [E] (2 screws).
5. Remove the front shift cover [F] (2 screws).
6. Remove the rear cover [G] (4 screws).
7. Remove the shift tray [H] (4 screws).
8. Remove the front and rear tray cover [I] (1 screws at the front, 2 screws
at the rear).
9. Remove the left cover [J] (4 screws).

A095/A096/A097 10-16 FSM

4.2 ALIGNMENT BRUSH ROLLER REPLACEMENT

[A]

Finisher
A379
[B]
[H]
[I]
[J]
[D]
[I]
[C] [H]

[E]
[F]

[G]

[F] [E]

1. Remove the rear cover.

2. Remove the main board [A] (15 connectors, 1 optics cable).
3. Remove the tension bracket [B] (1 screw and 1 spring).
4. Remove the E-rings [C], slide out the pulleys [D], and remove 2 E-rings
[E] , then remove 2 bushings [F].
5. Remove the alignment brush roller assembly [G].
6. Remove the 2 E-rings [H] and remove the brush rollers [I].
NOTE: Do not lose the link keys [J].

FSM 10-17 A095/A096/A097

4.3 SENSOR REPLACEMENT

[E]

[A] [D] [B]

[C]

Stack Height Sensors

1. Remove the upper cover.
2. Remove the stack height sensor actuator [A] (1 screw).
3. Remove the bracket [B] (1 screw, 2 connectors).
4. Replace stack height sensor 1 [C] and stack height sensor 2 [D].
NOTE: When reinstalling the bracket [B], align the edge of the bracket
with the stay [E].

A095/A096/A097 10-18 FSM

Rev. 4/15/94
4.4 POSITIONING ROLLER REPLACEMENT

Finisher
A379
[A]

1. Open the front door and slide out the jogger unit.
2. Remove the positioning roller [A] (1 clip).

FSM 10-19 A095/A096/A097

Rev. 4/15/94
4.5 BELT TENSION ADJUSTMENT

[B]

[A]

[A, B]

[C]
1. Remove the rear cover and adjust the belt
[A] tension with tightener [a].
Remove the left upper cover, the upper
[a, b] cover, the front door, and the front shift
cover and the front supporting cover (2
screws). Adjust the belt [B] with tightener [b].

Standard: 6 mm deflection at 180 ± 100 g

[C] pressure.

2. Open the front door and slide out the jogger

unit. Adjust the belt [C] tension with
tightener [c].

[c] Standard: 8 mm deflection at 100 ± 30 g

pressure.

A095/A096/A097 10-20 FSM

[D]

Finisher
A379
[d]

150 ± 40 g

3. Open the front door and slide out the jogger unit. Adjust the belt [D]
tension with tightener [d].
Standard: 8 mm deflection at 150 ± 40 g pressure.

FSM 10-21 A095/A096/A097

LARGE CAPACITY TRAY
A380
1. SPECIFICATIONS

Copy Paper Size: A4 sideways

B5 Sideways
8 1/2" x 11" sideways
Copy Paper Weight: 64 ~ 105g/m2 16~24lb
Power Source: DC24V, 5V (from the copier)
Power Consumption: 40W
Dimensions (W x D x H ): 403 x 529 x 608mm
(15.9" x 20.8" x 23.9")

Large Capacity
Weight: 19.8kg (43.7lb)

A380
Tray
Tray Capacity: 3,500 sheets (may vary slightly depending on
paper weight)

FSM 11-1 A095/A096/A097

2. MECHANICAL COMPONENT LAYOUT
6

4
1

1. Bottom Plate
2. Tray Drive Belt
3. Separation Roller
4. Transport Rollers
5. Feed Roller
6. Pick-up Roller

A095/A096/A097 11-2 FSM

3. ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the Point to
Point (Waterproof Paper) for the symbols and index numbers.

Symbol Name Function Index No.

Sensors
S50 Paper End Informs the CPU that there is no 129
paper on the LCT bottom plate.
S51 Paper Near End Informs the CPU that about 60 130
sheets of paper remain on the LCT
bottom plate.
S52 Paper Position Detects the paper position. 131

Large Capacity
S53 Tray Down Informs the CPU that the LCT 133
bottom plate is in the lowest

A380
Tray
position.
S54 Feed Controls the paper feed clutch 136
off-on timing and the pick-up
solenoid off timing.
S55 Lift Detects the correct paper feed 137
height.
Switches
SW11 Feed Unit Cover Detects if the feed unit cover is 128
open or not.
Note:* There are two switches, A
and B.
SW12 LCT Cover Detects if the LCT cover is open or 134
not.
Note:* There are three switches, A,
A and B.
SW13 Tray Down Lowers the LCT bottom plate. 135
Motors
M22 LCT Lifts and lowers the LCT bottom 132
plate to bring paper to the feed
position and allow loading of the
paper.
M23 Feed Drives all feed and transport rollers. 140
Others
SOL14 Pick-up Controls the up-down movement of 138
the pick-up roller.
MC9 Feed Starts paper feed from the LCT. 139
*See copier Point to Point diagram
coordinates J9 & J10.

FSM 11-3 A095/A096/A097

4. INSTALLATION PROCEDURE
4.1 ACCESSORY CHECK
Check the accessories in the box according to the following list:
Description Q’ty
1. Installation procedure...................................................................... 1
2. New Equipment Condition Report (for –17, –27 machines only).... 1
3. LCT feed unit................................................................................... 1
4. Small cover - left cover.................................................................... 1
5. Philips pan head screw - M4 x 6 ..................................................... 1
6. Philips pan head screw - M4 x 16 ................................................... 1
7. Tapping screw - M4 x 8................................................................... 1
8. Envelope - NECR (for –17 machine only)....................................... 1

A095/A096/A097 11-4 FSM

4.2 INSTALLATION PROCEDURE

[A] [B]

[B]

[C]
[A]
[A]

Large Capacity

A380
Tray
[E]

[D]

[F]

CAUTION: Unplug the copier power cord before starting the

following procedure.

1. Remove the four strips of tape [A].

2. Open the LCT cover [B] and remove the tape [C] fixing the paper trailing
edge stopper.
3. Remove the tray cushion [D] secured with two strips of tape [E].
4. Remove the LCT connector [F] (3 screws).

FSM 11-5 A095/A096/A097

[A]

[D]

[E]

[B]

[C]

[C]

[G]

[F]

5. Open the by-pass table [A] approximately 45 degrees and push the
stoppers [B] of the feed unit cover [C] by using a small flat head screw
driver [D], then remove the feed unit cover.
6. Remove the harness cover [E].
7. Install the LCT feed unit [F] to the copier (3 screws - M 4 x 6).

CAUTION: Do not pinch the harness [G] located below the by-pass
table.

A095/A096/A097 11-6 FSM

Rev.1/20/94

[D]

[D]
[C]
[B]

[G]
[A]

Large Capacity

A380
Tray
[E]

[F]
8. Install the LCT connector [A] to the copier.
1) Remove the three caps [B].
2) Set the two pins [C] of the LCT connector into the two holes [D] on the
LCT feed unit.
3) Install the LCT connector to the copier (3 screws - M4 x 16).

CAUTION: When installing the tray unit [A] to the LCT connector [B],
be careful not to pinch the harness between the feed unit
bracket [C] and the tray unit bracket [D], as shown below.

[C] [D]

[B] [A]

To prevent this, fix the harness with a piece of tape as shown on page 11-8
before installing the tray unit.

FSM 11-7 A095/A096/A097

Rev.1/20/94

Tape

9. Remove the screw fixing the upper cover hinge [E] then slide and
remove the LCT cover [F].
10. Remove the rear upper cover [G] (2 screws).

A095/A096/A097 11-8 FSM

Rev.1/20/94

[A]

[C]

[B]

Large Capacity
[D]

A380
Tray
11. Hold the upper stay [A] of the LCT and place the LCT on the plates [B] of
the LCT connector.

CAUTION: Properly place the LCT on the plate [B] of the LCT
connector.

12. Move the LCT forward so that the two holes on its assembly are
engaged by the two pins [C].
13. Secure the LCT to the LCT connector (3 screws - M 4 x 8).
14. Set the cap [D] in the front screw access hole.

FSM 11-9 A095/A096/A097

Rev.1/20/94

15. Connect the connectors.

[A]
1) Between the copier and the LCT (3 connectors).
• 13P white
• 13P red
• 16P white

2) Between the LCT and the LCT feed unit (2 connectors).

• 10P white
• 8P white

16. Secure the protective earth wire [A] on the copier.

A095/A096/A097 11-10 FSM

Rev.1/20/94

[B]

[A]

Large Capacity

A380
Tray
17. Install the rear upper cover [A] (2 screws).
18. Install the LCT cover [B] (1 screw).
19. Plug in the copier and check machine operation.
NOTE: The copier automatically recognizes that the LCT has been
installed.

FSM 11-11 A095/A096/A097

Rev.1/20/94
4.3 PAPER SIZE CHANGE
[A]

[A]

[C]
[B]

[D]

[D]

NOTE: A4/Letter sideways is the factory setting.

1. While covering two sensors [A] with your hand, press the tray down key
[B] to lower the bottom tray.
2. Remove the screws [C] fixing the front and the rear side fences [D].
3. Tilt the side fences to the right (front view) and lift to remove.
4. Position the side fences according to the paper size.
5. Fix the side plates (1 screw each).

A095/A096/A097 11-12 FSM

Rev.1/20/94
[C]
[A]

[B]
[B]

Large Capacity
B5 A4 LT

A380
Tray
6. Remove the clip [A] and pull out the shaft [B]. Position the paper trailing
edge stopper [C] according to the paper size.
7. Re-install the shaft [B] and the clip [A].
8. Enter SP mode as follows:

1) Press the clear mode key.

2) Enter "107".
3) Touch the clear/stop key for more than 3 seconds.

1 0 7 C

9. Touch the "SP Special Features"

key [D].

[D]

FSM 11-13 A095/A096/A097

Rev.1/20/94
10. Touch the "Next" key [A] five times
to select the paper size setting
mode (page 6), then touch the
[A] [C]
appropriate paper size of "LCT" [B].

[B]

11. Touch the "Index" key [C]. [D]

12. Touch the "Quit" key [D].

13. Check the copy quality and machine operation.

A095/A096/A097 11-14 FSM

Rev.1/20/94
5. REPLACEMENTS AND ADJUSTMENTS
5.1 PAPER FEED ROLLERS REPLACEMENT
[C]

[D]
[A]

Large Capacity

A380
Tray
[B]

1. Open the top cover [A].

2. Remove the pick-up roller [B] (1 snap ring).
3. Remove the feed roller [C] (1 snap ring).
4. Remove the separation roller [D] (1 snap ring).
NOTE: Do not touch the surface of the rollers with oily hands.
The paper feed rollers used in the LCT are different from rollers
used in the 1st, 2nd and 3rd feed units in the paper tray unit.

FSM 11-15 A095/A096/A097

Rev.1/20/94
5.2 LCT FEED CLUTCH REMOVAL

[A]

[F]

[C]

[B]

[E]

[D]

[B]

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

2. Disconnect the two connectors [B].
3. Remove the harness bracket [C] (2 screws).
4. Remove the bracket [D] with the LCT feed motor (3 screws).
5. Replace the LCT feed clutch [E] (2 Allen screws).
NOTE: When installing the LCT feed clutch, set the stopper pin on the
clutch in the cut-out [F] on the bracket.

A095/A096/A097 11-16 FSM

Rev.1/20/94
5.3 UPPER COVER SWITCHES

[A]

Large Capacity

A380
Tray
[B]

[C]

❶
❺
1. Remove the right cover [A]. ❹
❸
❷
2. Remove the front cover [B].
3. Remove the upper cover switches [C].
NOTE: When installing the switches, set the connectors correctly.
❶ Yellow
❷ Blue
❸ Green
❹ Small white
❺ Large white

FSM 11-17 A095/A096/A097

Rev.1/20/94
5.4 SIDE-TO-SIDE REGISTRATION ADJUSTMENT
[B]

[A]

- Rough Adjustment -
1. Loosen the two screws [A] fixing the stay [B].
2. Move the stay position to change the side-to-side paper position.

- Fine Adjustment -
1. Enter SP mode (refer to the service program access procedure) and
access the side to side adjustment mode ( 1 SP Adjustment - PAGE 4).

2. Adjust side to side registration by changing the SP mode data.

NOTE: Copies can be made in SP mode. Touch the "Copy in SP" key to
select the paper feed station.
Adjustment standard: less than ±2 mm difference between the original and
the copy.

A095/A096/A097 11-18 FSM

SORTER STAPLER
A374
1. SPECIFICATIONS
Paper Size for Bins: Sort or stack mode:
Maximum: A3, 11" x 17"
Minimum: A5, 51/2" x 81/2" lengthwise

Staple mode:
Maximum: A3, 11" x 17"
Minimum: B5, 81/2" x 11"
Paper Weight for Bins: Sort or stack mode:
52 - 93 g/m2, 14 - 25 lb

Staple mode:
52 - 80 g/m2, 14 - 21 lb
Number of Bins: 20 bins + proof tray
Bin Capacity: Sort mode: 30 sheets (A4, 81/2" x 11")
15 sheets (A3, 11" x 17")

Stack mode: 15 sheets

Sorter Stapler
Proof tray - 100 sheets
(52 – 81 g/m2, 14 – 22 lb)

A374
- 50 sheets
(82 – 128 g/m2, 23 – 34 lb)
- 30 sheets
(129 – 157 g/m2, 35 – 42 lb)
Stapler Capacity: From 2 to 20 sheets (80 g/m2, 20 lb) (2 to 10
sheets when using A3/11"x17" or B4/81/2"x14")
Stapling Position:

(Horizontal) (Diagonal)
a a

b b

a=b a = 10 ± 2 mm
= 6 ± 2 mm = 0.39" ± 0.08"
= 0.24" ± 0.08" b = 16 ± 2 mm
= 0.63" ± 0.08"

FSM 12-1 A095/A096/A097

Staple Replenishment: Cartridge exchange
(3,000 pieces/cartridge)
Power Source: DC 24V, 5V (form the copier)
Power Consumption: 50 W
Dimensions: 412 x 600 x 690 mm
(W x D x H) 16.2" x 23.6" x 27.1"
Weight: About 55.1 lb
(Main Frame : 48.5 lb
Mounting Frame: 3 kg, 6.6)

A095/A096/A097 12-2 FSM

2. COMPONENT LAYOUT
2.1 MECHANICAL COMPONENT LAYOUT

13 2

12
3

11

Sorter Stapler
6

A374
10

1. Proof Tray 8. Stapler

2. Proof Tray Exit Rollers 9. Grip Assembly
3. Vertical Transport Rollers 10. Bin Support Block
4. Turn Gate 11. Bins
5. Bin Transport Belt 12. Support Bin
6. Bin Transport roller 13. Jogger Bar
7. Bin Exit Roller

FSM 12-3 A095/A096/A097

2.2 DRIVE LAYOUT
23
22 1
21 2 3
20 4
19
5
18
6
17 7

16 8

9
15

14 10
13 11
12

4. Roller Drive Motor Pulley 11. Bin Lift Motor Pulley

3. Rear Roller Drive Belt 8. Bin Lift Drive Belt

7. Bin Lift Gears

2. Proof Tray Exit Roller
Pulley (Rear) 6. Bin Lift Gear/Pulley 21. Bin Drive Shaft

(Proof Tray Exit Roller) 20. Front Bin Lift

Pully
19. Proof Tray Exit Roller
Pulley (Front) 12. Rear Bin Lift Wire 16. Front Bin Lift
Wire
13. Rear Bin Support
18. Front Roller Drive Belt Block 22. Front Bin
Support Block
17. Vertical Transport 10. Jogger Motor Pulley
Drive Pulley
13. Lower Jogger Drive Belt
15. Bin Transport Drive Gear
5. Jogger Drive Shaft
14. Bin Transport Belts
1. Upper Jogger
Drive Belt

23. Jogger Bar

A095/A096/A097 12-4 FSM

2.3 ELECTRICAL COMPONENT DESCRIPTION
Refer to the electrical component layout on the reverse side of the Point to
Point (Waterproof paper) for symbols and index numbers.

Index
Symbol Name Function
No.
Motors
Lifts and lowers the bins via a belt, gears, and
M1 Bin Lift 23
wires.
Drives the jogger bar to jog the copies against
M2 Jogger 20
the front side plate.
Drives the grip assembly forward and backward
M3 Grip into the bin to grip the copies and bring them to 13
the stapling position.
M4 Stapler Feeds the staples and drives the stapler hammer. 12
Drives the proof tray exit and vertical transport
M5 Roller Drive 1
rollers, and bin transport belts.
Circuit Board
PCB1 Main Control Controls all sorter stapler functions. 18
Solenoid

Sorter Stapler
Opens and closes the turn gate to direct the
SOL 1 Turn Gate 6
copies into either the proof tray or the bins.

A374
Sensors
Monitors the rotation of the bin lift motor by
S1 Bin Lift Timing -1 24 or 25
detecting the timing disk.
Controls the stop timing of the bin lift motor so
S2 Bin Lift Timing -2 that the bin lift timing sensor -1 can detect the 24 or 25
timing disk properly.
S3 Jogger H.P. Detects if the jogger bar is in the home position. 19
S4 Paper Detects if copies are under the hammer. 8
Detects if there is paper in the bins (light emitting
S5 Bin (LED) 3
element).
Detects if there is paper in the bins (light
S6 Bin (Photo transistor) 17
receiving element).
Detects if the grip assembly is in the home
S7 Grip H.P. 16
position.
Detects if all the bins are in the down (home)
S8 Bin H.P. 15
position.
S9 Bin Exit Detects paper jams at the bin exit area. 5
S10 Proof Tray Exit Detects paper jams at the proof tray exit area. 4
Monitors the roller drive motor speed by
S11 Roller Drive Timing 2
detecting the timing disk.
Switches
Stops the bin lift motor when this switch detects
SW1 Upper Lift Limit 22
the upper limit position of the bins.
Stops the bin lift motor when this switch detects
SW2 Wire Tension the lower limit position of the bins through the bin 21
lift wire tension.

FSM 12-5 A095/A096/A097

Index
Symbol Name Function
No.
SW3 Front Door Cuts the dc 24 V line when the front door is open. 14
Cuts the dc 24 V line when the sorter stapler unit
SW4 Sorter Stapler Set 7
is open.
SW5 Staple End Detects the staple end condition. 10
SW6 Staple Guide Detects if the staple guide plate is closed. 9
Detects if the staple hammer is in the home
SW7 Staple H.P. 11
position.

A095/A096/A097 12-6 FSM

3. INSTALLATION PROCEDURE
3.1 ACCESSORY CHECK
Check the accessories in the box according to the following list:
1. Harness Cover ........................................................................1
2. Proof Tray ...............................................................................1
3. Staple Cartridge ......................................................................1
4. Decal Switch ...........................................................................1
5. Fiber Optics Cable ..................................................................1
6. Staple Position Decal ..............................................................1
7. Stepped Screw........................................................................1
8. Philips Truss Head Screw – M4 x 6 ........................................3
9. Philips Truss Head Screw – M4 x 14 ......................................4
10. Grounding Screw with Toothed Washer – M4 x 6 ..................1

Sorter Stapler
11. Envelop – N.E.C.R. (for U.S.A.) ..............................................1

A374
12. Installation Procedure .............................................................1
13. Upper Entrance Guide ............................................................1
14. Lower Entrance Guide ............................................................1
15. Philips Pan Head Screw – M4 x 20.........................................4
16. Tapping Screw – M4 x 20 .......................................................4

FSM 12-7 A095/A096/A097

3.2 INSTALLATION PROCEDURE
(for Machine Code:A095 copier)

[A]

[B]
[A]

[A]
[C]

CAUTION: Unplug the copier power cord before starting the

following procedure.

1. Remove the strips of tape [A] and open the front door [B].
2. Remove the strips of tape [C] from the staple unit and close the front
door.

A095/A096/A097 12-8 FSM

[B]

[A]

[A] [C]

[E]

[F]

Sorter Stapler
A374
[C]

[D]

3. Remove the cover plates [A] from the left cover.

NOTE: Do not remove the cover plates [B].
4. Release the lock lever [C] of the sorter stapler and unhook the S/S
mounting frame [D] as shown.
5. Install the upper guide plate [E] (2 screws – M4 x 6) and the lower guide
plate [F] (2 screws – M4 x 6) onto the S/S mounting frame.

FSM 12-9 A095/A096/A097

[B]
[C]

[D]

[A]

[G]

[E]
[F]

6. Install the S/S mounting frame [A] on the copier as shown

(4 screws – M4 x 20).
NOTE: When hooking the S/S mounting frame on the left side of the
copier, make sure that the positioning hooks [B] of the frame are
properly inserted in the positioning holes [C] of the copier.
7. Install the sorter stapler [D] on the S/S mounting frame (2 hinge pins at
the rear).
8. Connect the link lever [E] with the sorter stapler by using stepped screw
[F], and then close the sorter stapler.
9. Install the proof tray [G] (1 screw – M4 x 6) as shown.

A095/A096/A097 12-10 FSM

[A]

[E]

[G]

[D]

Sorter Stapler
[H]
❇

A374
[F]

[C]
❇

[B]

10. Remove the rear cover [A] (4 screws) of the sorter stapler.
11. Couple the fiber optics cable connector [B] to DC1002 [C] on the Sorter
Stapler Main PCB.
12. Couple the fiber optics cable connector [D] and the connector [E] to the
mainframe.
13. Secure the protective earth wire [F] on the bracket [G] (1 protective earth
screw with spring washer).
14. To prevent the fiber optic cable being pinched by cover, round the fiber
optic cable through the wire saddles [H] three times as shown.

CAUTION: Do not bend the fiber optic cable.

FSM 12-11 A095/A096/A097

[B] [A]

[C]

15. Install the sorter stapler rear cover [A] (4 screws).

16. Install the harness cover [B] (2 truss screws – M4 x 6) on the sorter
stapler (2 truss head screws)
17. Stick the staple position decal [C] on the Dual Job Feeder (DJF) as
shown. (If there is no DJF, stick it on the corresponding position of the
platen cover.)

A095/A096/A097 12-12 FSM

[C]

[A]
[B]

[D]

Sorter Stapler
A374
[C]

18. Open the front door of the sorter stapler and swing the staple unit [A] up.
19. Remove the green plastic clip [B] from the staple cartridge [C] and
correct the position of the staple sheet [D] if necessary.
20. Install the cartridge in the stapler while holding the staple unit.
21. Set the staple unit at the original position, close the S/S front door, and
plug in the copier.
22. Turn on the copier main switch and test the operation of the sorter
stapler.
NOTE: The stapler will not be stapling for the first 10 or so copies until
the first staple comes to the proper position from the cartridge.

The copier automatically recognizes that the sorter stapler has

been installed.

FSM 12-13 A095/A096/A097

4. SERVICE TABLE (MAIN CONTROL BOARD)
4.1 DIP SWITCHES
DIP SW 100
1 2 3 4 5 FUNCTION Remarks
0 0 0 0 0 Standard
1 0 0 0 Sorter Free Run #1
*1 0 1 0 0 Staple Free Run #2
1 1 0 0 Sorter&Staple Free Run #3
0 0 0 0 1 Bin Sensor Adjustment

NOTE:*1 Confirm the setting from DIP SW 100 -2 to -5 before turning on

DIP SW 100 - 1 (Start SW function).
Turn off DIP SW 100 - 1 to stop the function.
Remarks
#1 The roller drive motor turns on.
The sorting operation is repeated from the 1st bin to the 20th bin.
Operated components:• Turn gate solenoid
• Bin lift motor
• Jogger motor
#2 The stapling operation is repeated from the 1st bin to the 20th
bin. When there is no paper in a bin, the stapling operation is
skipped for that bin.
Operated components:• Bin lift motor
• Grip motor
• Stapler motor
#3 #1 and #2 are repeated together.
Combinations other than those above are used at the factory.
4.2 LED and Variable Resistor
LED No. VR No. FUNCTION
100 100 Adjusts bin sensor sensitivity.

4.3 TEST POINT

Number FUNCTION
TP100 GND
TP101 +24V
TP102 +5V

A095/A096/A097 12-14 FSM

5. REPLACEMENT AND ADJUSTMENT
5.1 STAPLER REMOVAL

[A]

[B]
[C]

Sorter Stapler
A374
[D]

1. Open the front door [A] of the sorter stapler and swing the staple unit [B]
up.
2. Remove the staple unit cover [C] (1 screw).
3. Remove the stapler [D] (1 screw and 1 connector).

FSM 12-15 A095/A096/A097

5.2 GRIP ASSEMBLY REMOVAL

[A]

[C]
[B]

[D]

1. Remove the proof tray [A] (1 screw).

2. Swing out the sorter stapler and disconnect the link lever [B] (1 stepped
screw).
3. Remove the front cover [C] (remove 2 screws and loosen 2 screws).
4. Remove the grip assembly [D] (2 screws and 1 connector).

A095/A096/A097 12-16 FSM

5.3 BIN REPLACEMENT

[B]
[A]

Sorter Stapler
A374
[C]

1. Remove the sorter stapler from the copier.

2. Remove the proof tray [A] (1 screw).
3. Remove the jogger bar [B] as shown.
4. Remove the upper securing screw of the bin link [C] (1 screw each).

FSM 12-17 A095/A096/A097

[C]

[D]

[A]

[B]

5. Remove the support bin [A] and bins [B].

(1) Hold the bin [A or B] with both hands.
(2) Push the bin forward until the wheels [C] reach the bend.
(3) Push the left side of the bin forward and pull that side up.
(4) As you pull the left side up, the right wheel will leave its track.
(5) When the left wheel reaches the slot [D], pull the bin out.

A095/A096/A097 12-18 FSM

[C]

[E]

[D]

[A]

[B]

Sorter Stapler
A374
6. Install the support bin [A] and bins [B].
(1) Hold the bin top side up with both hands.
(2) Tilt the bin so the left side is higher then the right side.
(3) Pass the left wheel [C] through the slot [D], at the same time, pass
the right wheel [E] just below the stapler opening.
(4) Set the left wheel into the left track, then push the right wheel into the
right track.

FSM 12-19 A095/A096/A097

5.4 BIN LIFT WIRE REPLACEMENT
5.4.1 Wire Removal [A]

[C]

[B]

[D]

[E]

1. Remove the sorter stapler from the copier.

2. Remove the following parts:
• Proof Tray [A] (1 screw).
• Front Cover [B] (loosen 2 screws and remove 2 screw)
• Rear Cover [C] (4 screws)
• Support Bin [D] (see Bin Replacement)
• Bins [E] (see Bin Replacement)

A095/A096/A097 12-20 FSM

[B]
[D] [E] [A]

Sorter Stapler
A374
[F]
[C]

<Front side>
3. Swing the bin shaft cover [A] as shown (2 screws and 1 connector)
4. Remove the 3 fixing screws of the stapler unit [B].
5. Remove the bin support block stopper [C] as shown.
6. Remove the wire pulley [D] (1 E-ring).
NOTE: Be careful not to lose the parallel pin [E].
7. Remove the bin lift wire [F].

FSM 12-21 A095/A096/A097

[B]
[A]

[E]

[D]

[C]
<Rear side>
8. Remove the main control board [A] (1 screw, 13 connectors and 6
locking supports).
9. Remove the bin lift shaft cover [B] (2 screws).
10. Remove the timing sensor bracket [C] (1 screw).
11. Remove the bin drive bracket [D] (1 grounding screw, 1 connector and 2
wire saddles).
12. Remove the bushing [E].

A095/A096/A097 12-22 FSM

[C]

[B]

Sorter Stapler
A374
[A]
[D]

12. Remove the bin lift block stopper [A] as shown.

13. Remove the wire pulley/gear [B] (2 E-rings).
NOTE: Be careful not to lose the parallel pin [C].
14. Remove the bin lift wire [D].

FSM 12-23 A095/A096/A097

5.4.2 Wire Installation

[B] [A] [E] [D]

[K]

[I]
[F]
[G]
[Rear]
[P] [Q] [E] [D]
[J] [A]
[H] [O]
[Front]

[Q]
[L]
[C]
[F] [G]

[P]

[H] [M] [N]

[F]
[A]
550.4 mm (21.67") 877.6 mm (34.55") [P]

1. Put the bead [A] at the end of the wire in the slot of the wire pulley [B, C],
2. Insert the parallel pin [D] into the bin drive shaft [E] and then push in the
wire pulleys.
3. Wind the wire once as shown and put the bead [F] in the slot of the bin
support block [G].
4. Put the bin support block stopper [H] on the bin support block.
5. Place the wire on the pulleys [I/J/K, L/M/N/O] and put the bead [P] in the
slot of the bin lift shaft [Q].

A095/A096/A097 12-24 FSM

5.5 VERTICAL TRANSPORT UNIT REMOVAL

[C]

[B]
[D]

[A]

[F]
[E]

Sorter Stapler
A374
[G]

1. Remove the sorter stapler from the copier.

2. Remove the proof tray, the front cover, the rear cover, and the upper
cover.
3. Remove the upper hinge [A] (2 screws) and the sorter stapler set switch
bracket [B] (1 screw).
4. Remove the grounding screw [C] and disconnect the main harness [D] (5
connectors and 3 harness clamps).
5. Remove the timing belt [E] from the pulley [F].
6. Remove the vertical transport unit [G] (8 screws).

FSM 12-25 A095/A096/A097

5.6 MAIN CONTROL BOARD REPLACEMENT AND
ADJUSTMENT
5.6.1 Main Control Board Replacement

[A]

1. Remove the proof tray and the rear cover.

2. Disconnect the main control board connectors and fiber cable.
3. Replace the main control board [A] and connect the connectors.
4. Turn on the copier main switch.
5. Adjust the bin sensor (see next page).
6. Turn off the main switch.

A095/A096/A097 12-26 FSM

5.6.2 Bin Sensor Adjustment

[C]

[B]

Sorter Stapler
A374
[A]

1. Turn on DIP SW100-5 [A]

2. If LED100 [B] is on, turn VR100 [C] counterclockwise until LED100 turns
off.
3. Turn VR100 clockwise until LED100 just turns on.
4. Turn off DIP SW100-5.

FSM 12-27 A095/A096/A097

5.7 BELT TENSION ADJUSTMENT

[A]

[B]

a: Bending (mm/inches)

1. Remove the respective covers for the following belt tension adjustment:
Timing Belt [A]
(Roller Drive Motor) ..................................... Proof Tray
Rear Cover
Timing Belt [B]
(Grip Motor) ................................................. Proof Tray
Front Cover
2. Adjust the timing belt tension as follows:

Timing Belt Bending Pressure

A 4 mm (0.16") 250±50 g
B 45 mm (1.77") 250±50 g

A095/A096/A097 12-28 FSM

TECHNICAL SERVICE BULLETINS
BULLETIN NUMBER: 6645/6655-001 01/20/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SC502, 508, 510, 511

SYMPTOM:
SC502,508,510 or 511 is displayed.

CAUSE:
When the tandem paper tray is closed roughly, it bounces slightly to the front disengaging the drawer
connectors.

FIELD COUNTERMEASURE:
1. Instruct the operator to gently push the tandem tray until it stops. If any of the above mentioned Service
Codes are present, instruct the operator to pull the tray out and gently push the tray back in until it stops
and then turn the main power switch "OFF" and then "ON".

2. Apply silicone grease (G-501) to the points called out in the illustrations below. This reduces the friction
between the tandem tray and the guide rail which helps the lock lever to position the tandem tray at the
correct position. If the tandem tray bounces slightly to the front, the lock lever pushes the lock plate to
move the tray back to the correct position.

Grease

Grease

Lock Lever

Lock Plate

PRODUCTION COUNTERMEASURE:
1. Grease is applied at the factory where described in the Field Countermeasure above.

Continued...
Tech Service Bulletin No. 6645/6655-001
Page 2 of 2

2. To make the tray movement smoother, the roller [A] on the lock lever is changed from a resin roller to a
metal roller with bearings.

[A]

[B]

[C]

3. The spring has been changed so that the tension applied to the tray lock lever is increased from 1.5kgf
to 3.0kgf

NOTE: Because the spring tension has been increased, to keep the tandem tray drawing force constant, the
lock plate [C] shape is flatter.

[C]
BULLETIN NUMBER: 6645/6655-001 REISSUE 07/11/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SC502, 508, 510, 511

SYMPTOM:
SC502,508,510 or 511 is displayed.

CAUSE:
When the tandem paper tray is closed roughly, it bounces slightly to the front disengaging the drawer
connectors.

FIELD COUNTERMEASURE:
1. Instruct the operator to gently push the tandem tray until it stops. If any of the above mentioned Service
Codes are present, instruct the operator to pull the tray out and gently push the tray back in until it stops
and then turn the main power switch "OFF" and then "ON".

2. Apply silicone grease (G-501) to the points called out in the illustrations below. This reduces the friction
between the tandem tray and the guide rail which helps the lock lever to position the tandem tray at the
correct position. If the tandem tray bounces slightly to the front, the lock lever pushes the lock plate to
move the tray back to the correct position.

Grease

Grease

Lock Lever

Lock Plate

PRODUCTION COUNTERMEASURE:
1. Grease is applied at the factory where described in the Field Countermeasure above.

Continued...
Tech Service Bulletin No. 6645/6655-001 REISSUE
Page 2 of 2

2. To make the tray movement smoother, the roller on the Lock Arm is changed from a resin roller to a
metal roller with bearings.

Tandem Tray Lock Arm

Tandem Tray Left Rail
Tandem Tray Lock Spring

Left Rail Bracket

3. The Tandem Tray Lock Spring and the Left Rail Bracket have been changed so that the tension applied
to the tray lock lever is increased from 1.5kgf to 3.0kgf

NOTE: Because the spring tension has been increased, to keep the tandem tray drawing force constant, the
lock plate on the Left Rail is flatter.

Old New

Left Rail Lock Plate is flatter

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
AA060570 Tray Lock Spring - 20mm (Tandem) 0 1
1 97 30
AA060592 Lock Spring - Tandem Tray 0 1
A0966261 Left Rail 0 1
1 97 20
A0966241 Left Rail - Tandem Tray 0 1
A0966266 Tray Lock Arm 0 1
1 97 19
A0966247 Lock Arm - Tandem Tray 0 1
A0966246 Left Rail Bracket 0 1 97 35*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
BULLETIN NUMBER: 6645/6655-002 01/20/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow. ⇒

• Table of Contents (vii) Updated Information

• 6-17 Updated Information
• 6-31 thru 6-36 Additional Information
BULLETIN NUMBER: 6645/6655-003 01/20/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow. ⇒

• 3-4 Updated Information

• 3-6 Updated Information
• 7-7 Updated Information
• 11-7 Updated Information
BULLETIN NUMBER: 6645/6655-004 01/20/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: DJF FEED ROLLER ASSEMBLY

SYMPTOM:
The feed roller assembly is removed along with a misfed original.

CAUSE:
When a jammed original is pulled to the front, the feed rollers [A] are pulled to the front and the joint part [B]
comes out from the drive shaft.

SOLUTION:
The middle roller [C] position has been changed (to the front) as shown below.

[B]
[C]
[A]

Guide Plate
[B]

Front

Old

[C]

New

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow. ⇒

• 7-15 Updated Information

BULLETIN NUMBER: 6645/6655-005 02/04/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SOFTWARE MODIFICATION

SYMPTOM:
1. - Registration Jam when copying on 4 hole punched paper
The jam occurs during continuous copy runs when the holes in the paper match the location of the
registration sensor.

2. - Process Control data initial setting does not function with the weekly timer activated
For customers who never turn the main switch "OFF", the auto process control does not work. After
approximately 150k copies, dark copies followed by copies with dirty background are produced.

3. - ADS does not function with the last original fed through the RDH
The 4th ID level is selected for the last original fed through the RDH. If multiple sets of copies are made,
only the last original of the first set is affected.

4. - SC742 (only with the RDH and Finisher system)

When the following conditions are met, the positioning roller [A] interrupts the paper feed out pawl [B],
resulting in an SC742 condition.
● The previous customer selected the staple mode and did not clear the staple mode after job completion
● Only one original is being copied
● More than three copies are made (the problem occurs after feeding 4 or more copies)

[A]

[B]

[A]

NOTE: After the software modification,when the above conditions are met, the interval between copies
becomes longer to prevent the interruption between the positioning roller [A] and the paper feed out
pawl [B]. Only in this case, the CPU reduces the copy speed from 55cpm to 22.5cpm (A4/Letter
sideways). If the above three conditions are not met, the copy speed is 55cpm.

5. - Two roller marks on halftone image areas

When the following conditions are met, light lines appear on the latter half of the image as shown below.
● Last paper fed from the duplex tray
● There is halftone image area on the latter
half of the front side copy

Continued...
Direction of paper travel
Tech Service Bulletin No. 6645/6655-005
Page 2 of 3

The transport clutch turns off when the paper is still being transported by the duplex transport rollers [A].
Under this condition, the leading edge of the paper is transported by the vertical transport rollers [B] and the
paper is rubbed by the duplex transport rollers [A].

[B]

[A]

6.- Modes clear when the key counter is disconnected

Normally, the selected modes are automatically cleared when the key counter is disconnected. This
modification will enable the previous mode to be held even if the key counter is disconnected. The
default setting is still the same as before (mode clear function).
● How to access this mode: [A]

1. Enter SP adjustment mode. 00000

2. Touch the "Prev." key (access page 16 - extra page).
3. Touch the "Set" key [A] of the 4th item.
4. Input "1".
5. Press the enter key on the numeric keypad. 00001
CAUSE:
Software

SOLUTION:
Replace the ROMs on the Main Control Board
IC NUMBER OLD PART NUMBER NEW PART NUMBER
IC 120 (4M Bite) A0965121K A0965151
IC 133 (1M Bite) A0966123K A0965153

ORDERING PROCEDURE:
To obtain the new Main Control Board ROMs (P/N A0965151 and A0965153) at no charge, please complete
and fax the attached form to Technical Services or download a Hex file for local programming via the Ricoh
Technical Services BBS (refer to Service News and Information No.147).

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3353520001 and A3363520001 respectively
will have the new software installed during production.

Continued...
Tech Services Bulletin No. 6645/6655-005
Page 3 of 3

SUBJECT:
Fax this entire page in "DETAIL" mode ATTN: Technical Services - Copier

Fax Number: 201-882-3960

Each serial number given will represent a request for one set of Main Control Board ROMs (P/N A0965151
and A0965153).
Serial Number (s)
FT6645/6655 RDH
1
2
3
4
5
All serial number information will be verified before shipment is made.

NOTE: Old ROM’s must be returned within five (5) days to:
Ricoh Corporation
10 Bloomfield Avenue
P.O. Box 691
Pinebrook, New Jersey 07058

ROM INSTALLATION NOTE:

When installing a new ROM, check the following before applying power to the unit as serious damage may
occur to the new ROM and PCB.
Power "OFF" the unit before installing or removing a ROM (do not unplug machine)
• Ensure all legs of the ROM are straight and aligned with their corresponding socket hole before placing
the ROM completely in its socket
• Ensure the ROM notch matches the notch etched in the circuit board (Pin 1 to Pin 1)
• When more than one ROM is being installed, ensure the proper ROM is inserted in the correct socket
• REMINDER: Practice safe static control (refer to Factsline #096)
If you are not completely sure on how to install a new ROM in a Ricoh unit call Ricoh Technical Services
before proceeding with the installation.

PLEASE TYPE OR PRINT CLEARLY.

DEALER NAME:
ADDRESS:
CITY: STATE: ZIP CODE:
ATTENTION: PHONE # :
DEALER ACCOUNT NUMBER:
BULLETIN NUMBER: 6645/6655-006 04/04/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued to update all FT6645/6655 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655 Parts Catalog documentation.

• UPDATE NO. 1 - PARTS CATALOG CORRECTIONS/ADDITIONS - Please add the following

corrections and additions to your Parts Catalog

1. Correct the illustration on page 20 of the Parts Catalog as shown.

2

Correct
Incorrect

2. Correct the illustration on page 80 and add the following part information to page 81.

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
05730040E Hexagon Headless Set Screw - M3 x 40 n➞n+1 81 112*
* DENOTES NEW ITEM

Continued...
Tech Service Bulletin No. 6645/6655-006
Page 2 of 2

3. Add the following to your Parts Catalog:

Key Counter Holder Set

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A5090010 Key Counter Holder Set 1 13 50
A0969521 Editing Sheet - LT 13 51
A0969520 Editing Sheet - A4 13 52

4. Add the index number 33 to the illustration on page 60 as indicated .

33

5. Please correct the part number on page 87 as follows:

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION PAGE ITEM
AX400049 AX400053 Anti-condensation Heater - 240V 18W 87 31

Continued...
BULLETIN NUMBER: 6645/6655-007 04/04/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: ELECTRICAL MALFUNCTIONS DUE TO IMPROPER GROUNDING

SYMPTOM:
1. The scanner overruns home position and contacts the optics frame.

2. The exposure lamp turns off suddenly and the scanner stops during copying causing the copy paper to
stop in the fusing unit. A partially black solid image appears on the copy paper because the exposure
lamp has turned off during the copy process.

3. When the above mentioned fuser jam is removed, the selected copy modes are cleared.

4. The erase lamp turns on at the wrong time and position resulting in partially void copy image.

CAUSE:
Poor ground connection at one or more of the following points:

6. Main charge corona unit

1. By-pass paper size sensor bracket
7. Fusing roller anti-static brush
2. Development unit grounding spring
8. Drum shaft grounding terminal
3. Development unit grounding spring plate
9. Cleaning brush roller grounding wire
4. ID sensor board bracket

5. Pick-off pawl shaft

SOLUTION:
Ensure proper grounding at all of the following points:

1. The ground wire [A] at the by-pass paper size sensor [B].

[B]
[A]

Continued...
Tech Service Bulletin No. 6645/6655-007
Page 2 of 4

2. The grounding spring [C] at the grounding plate [D] (this prevents excessive static charge generated by
the developer from arcing between the development unit and the registration guide plate)

Development Unit
[D]

[C]

NOTE: From December 1993 production, the grounding spring inner diameter has been reduced so that it is
properly secured and positioned by the stepped screw.

3. The grounding spring plate [A] to the development unit

[A]

Development Unit

4. The ID sensor to the ID sensor board bracket via the ground strap (this prevents static electricity from
arcing between the copy paper and the ID sensor board bracket).

Pick-off Pawl Shaft

Tension Spring

Ground Strap

ID Sensor Board Bracket

5. The pick-off pawl tension spring (above) has been electrically connected to the ID sensor board bracket
since the first production machines in December, 1993 (this prevents arcing between the copy paper
and the pick-off pawl shaft).

NOTE:
A kit containing item 2 (Development unit grounding spring) and item 5 (Pick-off pawl shaft) has been made
available. This kit, P/N A0969900, may be acquired through normal NSPC channels.

Continued...
Tech Service Bulletin No. 6645/6655-007
Page 3 of 4

Spring replacement procedure

[A] [B]

[C]
[D]

1) Remove the ID sensor Bracket [C] (2 screws).

2) Remove the old tension spring (1 E-ring).
3) Install the new tension spring (1 E-ring)
4) Re-install the ID sensor board bracket. Secure the hook [D] at the end of the spring
to the screw fixing the ID sensor board bracket.

6. Ensure the main charge corona is set properly and is secured to the drum stay with a screw (this
prevents poor contact at the rear terminal which could result in high voltage leakage).

7. The anti-static brush [A] must be in contact with the edge of the fusing roller (this prevents static from
accumulating on the fusing roller and arcing to nearby metal parts).

[A]

Fusing Unit

Continued...
Tech Service Bulletin No. 6645/6655-007
Page 4 of 4

8. If the drum shaft grounding terminal [B] is not set properly or has too much wear (does not contact the
drum shaft), incomplete grounding may occur (this results in electrical malfunction).

[B]

NOTE: The drum shaft grounding terminal should be replaced every 360k copies.

9. If the grounding wire [A] is not installed correctly, static charge on the cleaning brush may arc to nearby
parts (this results in electrical malfunction).

[A]

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒

• 6-38 THRU 6-41 Additional Information

BULLETIN NUMBER: 6645/6655-008 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PICK-OFF PAWLS

SYMPTOM:
1. The pick-off pawls touch and damage the transfer belt.

2. Toner drops onto copies below pick-off pawls.

CAUSE:
1. While removing jammed paper around the drum, the operator moves the pick-off pawls out of the
correct position.

2. Toner accumulates on the head of the pick-off pawls and drops to the copy paper below.

SOLUTION:
1. The shape of the pick-off pawls have been changed to prevent them from contacting the transfer belt.

2. The material of the pick-off pawls has been changed from metal to resin.

NOTE: Because the material of the pick-off pawls has changed to resin, the pick-off pawls will wear down
with long usage. To prevent drum filming and the formation of gray lines on the copy image, the
pick-off pawls must be replaced every 240K copies.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963510 A0973510 Lower Drum Unit 1➞1 1 61 *
AD025015 AD025018 Pick-Off Pawl 2➞2 1 61 35

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655-008
Page 2 of 2

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒

• 4-58 Updated Information

• 5-55 Updated Information
BULLETIN NUMBER: 6645/6655-009 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: VERTICAL BLACK LINE

SYMPTOM:
Vertical black lines on non-operator side of copies (see illustration [E]).

CAUSE:
The cleaning blade side seals are deformed during or prior to installation. If there is a gap between the
cleaning blade [A] and the side seals [B], air flows from the front side [C] to the back side [D] of the cleaning
blade through the gap. This air carries a small amount of toner to the back side of the cleaning blade where
it gradually accumulates. This accumulated toner drops to the drum creating black lines [E].

(paper travel)

Correct Condition Incorrect Condition

[B]

[E]

Drum Drum
[A] [C]

[D]
Drum Drum

SOLUTION:
1. Clean the back side of the cleaning blade.

2. Apply setting powder or toner to the side seals where they touch the cleaning blade.

3. Install the cleaning blade.

4. Confirm that the cleaning blade is not deformed.

BULLETIN NUMBER: 6645/6655-010 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒

• 4-59 Updated Information

BULLETIN NUMBER: 6645/6655-011 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SHIPPING RETAINERS

SYMPTOM:
Scanner and/or drum damage after machine is transported after initial installation.

CAUSE:
The Scanner Clamp [A] and/or the Transfer Belt Clamp [B] are not set prior to machine transportation.

[A]

[B]

SOLUTION:
Install the Scanner Clamp [A] and the Transfer Belt Clamp [B] as indicated prior to machine transportation.
These clamps are installed during production and should be retained with each machine.
BULLETIN NUMBER: 6645/6655-012 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒

• 1-2 Updated Information

• 4-10 Updated Information
• 4-12 Updated Information
• 4-24 Updated Information
• 4-25 Updated Information
• 4-44 thru 4-46 Updated Information
• 5-10 Updated Information
• 5-77 Updated Information
• 5-78 Updated Information
• 6-19 Updated Information
• 7-10 Updated Information
• 7-26 Updated Information
• 8-2 Updated Information
• 9-21 Updated Information
• 10-2 Updated Information
• 10-20 Updated Information
BULLETIN NUMBER: 6645/6655-013 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SCANNER FLAT CABLE, LENS COVER INSTALLATION

SYMPTOM:
Rubbing noise from lens unit during scanning.

CAUSE:
The scanner flat cable and the lens unit cover are installed too close to each other.

SOLUTION:
1. Loosen the two screws [C] fixing the lens unit cover.

2. Pull the lens unit cover [A] to the front.

3. Tighten the two screws [C].

4. Loosen the screw [D] fixing the scanner flat cable.

5. Turn the scanner flat cable [B] counterclockwise (it can only rotate slightly).

6. Tighten the screw [D].

[A] [D] [B] [A]

[B]

[C]
BULLETIN NUMBER: 6645/6655-014 04/15/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655 Parts Catalogs. This information should
be incorporated into all existing FT6645/6655 Parts Catalog documentation.

Bottle Guide Plate

• UPDATE NO. 1 - BOTTLE GUIDE PLATE -

To make setting of the
toner bottle easier, the
bottom guide plate has
been added to the bottle
holder as shown.

Bottle Holder

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0963245 Bottle Guide Plate 0➞1 57 34*
* DENOTES NEW ITEM

• UPDATE NO. 2 - FUSING DRIVE JOINT/GEAR - 31Z - To improve durability, the number of
engagement projections on the fusing drive joint has been increased from two to
four.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961169 A0961173 Fusing Drive Joint 1➞1 1 79 15
AB017292 AB017357 Gear - 31Z 1➞1 1 65 16

UNITS AFFECTED:

All FT6645/6655 copiers will use the Fusing Drive Joint and Gear as service replacement parts only.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
BULLETIN NUMBER: 6645/6655/6665-014 REISSUE 11/08/94
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655 Parts Catalogs. This information should
be incorporated into all existing FT6645/6655 Parts Catalog documentation.
Bottle Guide Plate

• UPDATE NO. 1 - BOTTLE GUIDE PLATE and SEAL-

To make setting of the toner bottle
easier, the bottom guide plate and
seal have been added to the bottle
holder as shown.

Bottle Guide Seal

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0963245 Bottle Guide Plate 0 1 57 34*
A0963246 Bottle Guide Seal 0 1 57 35*
09654008W Tapping Screw with Flat Washer - M4 X 8 n n+1 57 101
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354450503 and A3364460002 respectively
and all FT6665 copiers (from first production) will have the Bottle Guide Plate, Seal and Tapping Screw
installed during production.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued..
Tech Service Bulletin No. 6645/6655/6665-014 REISSUE
Page 2 of 2

• UPDATE NO. 2 - FUSING DRIVE JOINT/GEAR - 31Z - To improve durability, the number of
engagement projections on the fusing drive joint has been increased from two to
four.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961169 A0961173 Fusing Drive Joint 1 1 1 79 15
AB017292 AB017357 Gear - 31Z 1 1 1 65 16

UNITS AFFECTED:
All FT6645/6655 copiers will use the Fusing Drive Joint and Gear as service replacement parts only.
BULLETIN NUMBER: 6645/6655-015 05/24/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: KEY OPERATOR SERVICE TIPS

PROBLEM:
1. Paper misfeed at Tandem Tray press arms. 3. Paper misfeed at feed tray feed rollers

2. Paper misfeed in built-in LCT (1.5K LCT). 4. SC504

CAUSE:
1. 500 Sheets of thick paper are loaded into the left tray. When the paper stack is transported to
the right tray, some sheets may be caught by the press arms.

2. The end fence has been removed to allow A3 size paper feed. This prevents the top sheet,
which is returned to the tray by the FRR mechanism, from stopping at the correct position and
also results in too much load (because of heavier paper ) for the built-in LCT lift motor.

3. If adhesive labels are fed from the feed trays, the angle of the paper path may cause the label to
peel off the sheet and become stuck to the feed rollers.

4. The customer can load two stacks of copy paper in the Tandem Tray but they can NOT load the built-in
LCT in the same manner. Because there is no paper level detection for the improperly loaded area, the
LCT lift motor will continue to drive upward even though paper is already at the highest position
resulting in an SC504.

ACTION:
1. When using thick paper, do NOT stack the paper over the limit mark [A] even if there are less
than 500 sheets.

2. Do NOT remove the end fence [B] in the built-in LCT (1.5K LCT) to allow A3 size paper feed.

3. Adhesive labels should only be fed from the bypass feed tray; one sheet at a time.

4. Do NOT set copy paper at the left side of the end fence [B] of the built-in LCT (1.5K LCT).

[B]
[A]

Press Arms
Tandem Tray
1.5K LCT
BULLETIN NUMBER: 6645/6655-016 06/13/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: TONER END SENSOR FAILURE

SYMPTOM:
Light copies - toner hopper becomes empty - no "Toner End" indication.

CAUSE:
Defective Toner End Sensor.

Normally, the mylar [A] on the toner hopper agitator shaft scrapes the Toner End Sensor surface [B] to keep
the surface clean. However, if the pressure between the sensor and the mylar is too high, the sensor may
be damaged. If this occurs, the machine judges that there is toner in the hopper even if the hopper is empty.

[A]

[B]

FIELD COUNTERMEASURE:

We recommend performing step (2) of this countermeasure at machine setup / installation

(1) Replace the Toner End Sensor [A] [B]

(P/N AW310003).

(2) Since replacement of the cleaning mylar is

impossible, add two (2) 0.5mm washers [B]
as shown (P/N 07080030B: thickness =
0.5mm, inner diameter = 3.2mm, outer
diameter =6mm). This will reduce the
Toner Supply Unit
pressure between the toner end sensor and
the cleaning mylar. [A]

Continued...
Tech Service Bulletin No. 6645/6655-016
Page 2 of 2

PRODUCTION COUNTERMEASURE:
To improve the durability of the toner end sensor, the Cleaning Mylar’s flexibility has been increased
(the thickness has been decreased).

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354420001 and A3364420032 respectively
will have the new style Toner End Sensor Cleaning Mylar installed during production.

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 6-33 Updated Information

BULLETIN NUMBER: 6645/6655-017 05/24/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 3-11 Additional Information

• 4-14 Additional Information
BULLETIN NUMBER: 6645/6655-018 06/13/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655 Parts Catalogs. This information should
be incorporated into all existing FT6645/6655 Parts Catalog documentation.
[A]

• UPDATE NO. 1 - LCT LIFT MOTOR FUSE - As per field

request, the 125V/4A fuse on the
LCT Lift Motor PCB has been registered LCT Lift Motor
as a service part.
This fuse [A] is located beside the 5 pin
connector on the LCT Lift Motor PCB
and is labeled "F1".

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0699522 Fuse - 125V/4A 0➝1 49 24

• UPDATE NO. 2 - MAIN CONTROL BOARD - Due to software modifications, the part numbers for
the main control board and main control board ROMs have been changed.

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0955110 A0955112 Main Control Board - 115V (FT6645) 1➝1
A0955115 A0955117 Main Control Board - 230V (FT6645) 1➝1 89 10
1
105 *
A0965110 A0965112 Main Control Board - 115V (FT6655) 1➝1
A0965115 A0965117 Main Control Board - 230V (FT6655) 1➝1
A0965121 A0965151 IC - AM27C040 - 150DC 1➝1 1 105 1
A0965123 A0965153 IC - AM27C010 - 150DC 1➝1 1 105 2

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655-018
Page 2 of 2

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3353520001 and A3363520001 respectively
will have the new style Main Control Board and ROMs installed during production.

• UPDATE NO. 3 - CLEANING AGITATOR - Due to part standardization, the following parts have
been changed:
Old
1. The Cleaning Brush Mylar has been
changed to a metal type as shown.
New

Cleaning Agitator
2. The Cleaning Agitator has been
added as shown.
Agitator Bushing

Gear - 36Z
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963606 Cleaning Brush Seal 1➝0 61 16
1
A0963607 Brush Roller Bracket 0➝1 61 16
AA082059 Agitator Bushing 0➝1 61 47*
AB010340 Gear - 36Z 0➝1 61 48*
AD039057 Cleaning Agitator 0➝1 61 49*
07200040B Retaining Ring - M4 n➝n 61 103
09513006B Philips Screw with Flat Washer
0➝1 61 106
M3 x 6
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354440001 and A3364430119 respectively
will have the new style Brush Roller Bracket, Agitator Bushing and Gear installed during production.

• UPDATE NO. 4 - KEY COUNTER HOLDER SET - Due to a change in ordering and delivery
procedures, the Key Counter Holder Set is no longer available as a service part.
Instead, it has been newly registered as an optional product. The new
description, Key Counter Bracket Unit Type 1 (A509-01), can be ordered by using
EDP Code: 208901.

REFERENCE
OLD PART NO. DESCRIPTION QTY PAGE ITEM
A5090010 Key Counter Holder Set 1➝0 13 50
BULLETIN NUMBER: 6645/6655-018 REISSUE ★ 09/30/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655 Parts Catalogs. This information should
be incorporated into all existing FT6645/6655 Parts Catalog documentation.
[A]

• UPDATE NO. 1 - LCT LIFT MOTOR FUSE - As per field

request, the 125V/4A fuse on the
LCT Lift Motor PCB has been registered
as a service part. LCT Lift Motor

This fuse [A] is located beside the 5 pin

connector on the LCT Lift Motor PCB
and is labeled "F1".

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
★ A0969522 Fuse - 125V/4A 0©1 49 24

• UPDATE NO. 2 - MAIN CONTROL BOARD - Due to software modifications, the part numbers for
the main control board and main control board ROMs have been changed.

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0955110 A0955112 Main Control Board - 115V (FT6645) 1©1
A0955115 A0955117 Main Control Board - 230V (FT6645) 1©1 89 10
1
105 *
A0965110 A0965112 Main Control Board - 115V (FT6655) 1©1
A0965115 A0965117 Main Control Board - 230V (FT6655) 1©1
A0965121 A0965151 IC - AM27C040 - 150DC 1©1 1 105 1
A0965123 A0965153 IC - AM27C010 - 150DC 1©1 1 105 2

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655-018 REISSUE
Page 2 of 2

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3353520001 and A3363520001 respectively
will have the new style Main Control Board and ROMs installed during production.

• UPDATE NO. 3 - CLEANING AGITATOR - Due to part standardization, the following parts have
been changed:
Old
1. The Cleaning Brush Mylar has been
changed to a metal type as shown.
New

Cleaning Agitator
2. The Cleaning Agitator has been
added as shown.
Agitator Bushing

Gear - 36Z
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963606 Cleaning Brush Seal 1©0 61 16
1
A0963607 Brush Roller Bracket 0©1 61 16
AA082059 Agitator Bushing 0©1 61 47*
AB010340 Gear - 36Z 0©1 61 48*
AD039057 Cleaning Agitator 0©1 61 49*
07200040B Retaining Ring - M4 n©n 61 103
09513006B Philips Screw with Flat Washer
0©1 61 106
M3 x 6
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354440001 and A3364430119 respectively
will have the new style Brush Roller Bracket, Agitator Bushing and Gear installed during production.

• UPDATE NO. 4 - KEY COUNTER HOLDER SET - Due to a change in ordering and delivery
procedures, the Key Counter Holder Set is no longer available as a service part.
Instead, it has been newly registered as an optional product. The new
description, Key Counter Bracket Unit Type 1 (A509-01), can be ordered by using
EDP Code: 208901.

REFERENCE
OLD PART NO. DESCRIPTION QTY PAGE ITEM
A5090010 Key Counter Holder Set 1©0 13 50
BULLETIN NUMBER: 6645/6655-019 06/13/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SC600

SYMPTOM:
SC600 (Communication Error) is displayed on units with a Ricoh brand key counter installed.

CAUSE:
Static electricity arcs between the instruction decal (silver metallic color) and the key counter bracket.

[A]
[B]

[C]

SOLUTION:
1. The fixing plate [A] has been separated into two parts [B] so that the distance between the fixing plate
and the key counter increases.

2. A mylar [C] (P/N A5091064) has been added as shown.

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒

• 3-19 Updated Information

BULLETIN NUMBER: 6645/6655-019 REISSUE 02/09/95
APPLICABLE MODEL: FT6645/6655

SUBJECT: SC600
SYMPTOM:
SC600 (Communication Error) is displayed on units with a Ricoh brand key counter installed.

CAUSE:
Static electricity arcs between the instruction decal (silver metallic color) and the key counter bracket.

[B]
[A]

[C]

Holder Cover

SOLUTION:
1. The Plate Nut [A] has been separated into two parts (Right and Left Plate Nut) [B] so that the distance
between the Plate Nut and the Key Counter increases.

2. A mylar [C] has been added as shown.

REFERENCE
PART NUMBER DESCRIPTION QTY INT PAGE ITEM
A5091260 Holder Cover 0 1 0 12 59 *
A5091061 Left Plate Nut 0 1 0 12 57 *
A5091062 Right Plate Nut 0 1 0 12 58 *
A5091064 Key Counter Holder Mylar 0 1 0 12 56 *
* DENOTES NEW ITEM

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised pages have been highlighted by an arrow ⇒
• 3-19 Updated Information
BULLETIN NUMBER: 6645/6655-020 07/11/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: TOUCH PANEL DISPLAY POSITIONING

SYMPTOM:
The Touch Panel keys do not respond when touched.

CAUSE:
Rough adjustment of Touch Panel display positioning.

SOLUTION:
Precisely adjust the Touch Panel display position as follows:

1. Press the Interrupt key then press and hold the

[B]
Clear/Stop key for more than three (3) seconds.

2. Follow the guidance on the LCD.

[A]

2-1. Touch the upper left corner [A].

2-2. Touch the lower right corner [B].

NOTE: When touching the corners, use a small object such as a pen or pencil point but DO NOT press too
hard to avoid damage to the Touch Panel.

2-3. Touch a few positions to confirm whether the touch panel is correctly adjusted.

NOTE: When a portion of the Touch Panel is touched, the corresponding position indicates a "+" mark. If
this "+" mark is more than 7mm away from the precise point touched, press the Clear/Stop key and
start the adjustment procedure from the beginning.

2-4. If the adjustment is correct, press the Enter key .

NOTE: DO NOT skip step 2-4 of this procedure, otherwise, the result of the latest adjustment is ignored.

Continued...
Tech Service Bulletin No. 6645/6655-020
Page 2 of 2

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 6-42 Updated Information

BULLETIN NUMBER: 6645/6655-021 07/11/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655 Parts Catalogs. This information should
be incorporated into all existing FT6645/6655 Parts Catalog documentation.

• UPDATE NO. 1 - CLEANING SEAL - Due to parts standardization with the FT6665 drum unit, the
following seals have been added as shown below.

Cleaning Seal 3 Cleaning Seal 4 Cleaning Seal 1

Cleaning Seal 1

Cleaning Seal 2
Cleaning Seal 2

REFERENCE
OLD PART NO. DESCRIPTION QTY PAGE ITEM
AA151925 Cleaning Seal 1 0 3 61 50*
AA151926 Cleaning Seal 2 0 3 61 51*
AA151927 Cleaning Seal 3 0 3 61 52*
AA151928 Cleaning Seal 4 0 3 61 53*
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354420037 and A3364422004 respectively
will have the new Cleaning Seals installed during production.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655-021
Page 2 of 2

• UPDATE NO. 2 - SEAL - 0.05 X 26 X 285 - To improve the scanner flat cable movement, the Seal
(item #10, page 19) has been modified and the Guard Sheet has been added.
Guard Sheet

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961737 A0961738 Seal - 0.05 X 26 X 285 1 1 1 19 10
A0961875 Guard Sheet 0 1 27 27*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 3 - CLEANER CUSHION - To ensure the return movement of the charge corona wire
cleaner, the Cleaner Cushion has been added as shown.

Cleaner Cushion

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AA161034 Cleaner Cushion 1 59 42*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 4 - FLAT WASHER - M4 - To ensure paper end feeler movement, a Flat Washer has
been added as shown below.
Flat Washer - M4

112

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
07010040B Flat Washer - M4 n n+1 35 112*
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354430001 and A3364430009 respectively
will have the Flat Washer installed during production.
BULLETIN NUMBER: 6645/6655-022 07/11/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SMALL V L PATTERN

SYMPTOM:
Occasionally, the first scanner overruns the VL pattern during the process control data setting.

CAUSE:
When the room temperature is very low (less than 10° C or 50 ° F) the scanner drive wire is more rigid than
usual causing the first scanner to overrun the VL pattern.

SOLUTION:
To ensure the VL pattern is properly detected, an extension, called the Small VL Pattern, has been added as
illustrated below.

Left Scale

0 ∼ 1mm

VL Pattern Small VL Pattern

0 ∼ 1mm

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0961739 Small VL Pattern 1 19 27*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665-022 REISSUE ★ 12/22/95

APPLICABLE MODEL: FT6645/6655

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SMALL V L PATTERN

for reproduction of additional bulletins.

SYMPTOM:
Occasionally, the first scanner overruns the VL pattern during the process control data setting.

MECHANICAL
CAUSE:
When the room temperature is very low (less than 10° C or 50 ° F) the scanner drive wire is more rigid than
usual causing the first scanner to overrun the VL pattern.

SOLUTION:
To ensure the VL pattern is properly detected, an extension, called the Small VL Pattern, has been added as

ELECTRICAL
illustrated below.

★ Optics Frame (under Left Scale)

PAPER PATH
0 ∼ 1mm

★ VD Pattern Small VL Pattern

0 ∼ 1mm

FSM
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0961739 Small VL Pattern 1 19 27*
PARTS

* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
OTHER
BULLETIN NUMBER: 6645/6655-023 07/11/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: SC502, 510, 511

SYMPTOM:
SC502, 510, 511

CAUSE:
When the customer pulls out the tandem tray to clear a misfeed, paper may drop behind the tray. The paper
is then caught in the drawer connector at the rear side of the right tandem tray when the tray is pushed back
in. This may result in one or more of the following:

SC502 - Abnormal paper feed drive motor speed

SC510 - Abnormal tandem side fence home detection - stays OFF
SC511 - Abnormal tandem side fence home detection - stays ON

SOLUTION:
To ensure paper is not trapped behind the tandem tray, the Paper Guide Seal (P/N A0966694) and the
Paper Guide Sheet (P/N A0966693) have been added.

Paper Guide Seal

Tandem Tray

Paper Guide Sheet

Upper Front Stay

NOTE: The Paper Guide Sheet prevents paper from being caught by the Upper Front Stay.

Continued...
Tech Service Bulletin No. 6645/6655-023
Page 2 of 2

INSTALLATION PROCEDURE: Paper Guide Seal

Paper Guide Seal

1. Peel off the paper seal.

2. Adhere the Guide Seal as shown.

[A]

Paper Guide Sheet

1. Peel off the paper seals [A].

[B]

2. Adhere the Guide Sheet [B] as shown.

REFERENCE
OLD PART NO. DESCRIPTION QTY PAGE ITEM
A0966693 Paper Guide Sheet 1 97 36*
A0966694 Paper Guide Seal 1 45 31*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.

FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 6-36 Additional Information

• 6-37 Additional Information
BULLETIN NUMBER: 6645/6655/6665-024 09/30/94
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 4-35 Updated Information

Please replace Technical Service Bulletin No. 6645/6655-023 dated 08/02/94

with this bulletin. An error in sequencing was made during distribution of the
last bulletin package (Control #192) resulting in the existence of two (2)
consecutive 6645/6655-023 bulletins. Discard the 6645/6655-023 bulletin
dated 08/02/94 and retain the 6645/6655-023 bulletin dated 07/11/94.

NOTE: Since the updated Field Service Manual page (4-35 dated 08/02/94)
is not affected by this bulletin number correction, it is not being
distributed for a second time.
BULLETIN NUMBER: 6645/6655/6665-025 09/30/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: BLOWN DC POWER SUPPLY FUSES Downward pressure

Operation Panel here shorts the leads to
C103 as illustrated below.

SYMPTOM:
• Blank Operation Panel
• No power throughout machine

CAUSE:
Capacitor C103
If downward pressure is applied to the Operation
Panel (in the area of the shaded circle), the leads
to Capacitor (C103) on the Operation Panel are
shorted as illustrated.
Normal leads Shorted leads

TEMPORARY COUNTERMEASURE:
Push the capacitor (C103) toward the ROM as
illustrated. This will prevent the leads of C103 from shorting as downward pressure will now bend (C103) to
the left and not straight down

Push C103 toward the ROM

C103
ROM

Operation Panel PCB

ROM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured between Serial Numbers A3354450038 ~ A3354470233 and
A3364450001 ~ A3364460300 respectively may exhibit the above mentioned symptom. All FT6645/6655
copiers manufactured after Serial Numbers A3354470233 and A3364460300 respectively have had the
capacitor (C103) repositioned toward the ROM so that when pushed, the leads will not bend into each other.

PERMANENT COUNTERMEASURE:
A Capacitor with a straight lead will be used for future Operation Panel PCB production.
BULLETIN NUMBER: 6645/6655/6665-026 09/30/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/66645 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/66645 Parts Catalog documentation.

• UPDATE NO. 1 - KEY COUNTER JUMPER CONNECTOR - As per request from the field, the Key
Counter Jumper Connector has been registered as a service part.
Key Counter Jumper Connector

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0965464 Key Counter Jumper Connector 0©1 12 53*
* DENOTES NEW ITEM

* Operation Panel

• UPDATE NO. 2 - OPERATION PANEL -

Please correct your parts
catalog as follows:
#24

#23
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665-026
Page 2 of 2

Part Number Description Quantity Parts Catalog

Index No. Page

A0961461 Operation Panel Ass’y - LT

1 * 17
Incorrect A0961462 Operation Panel Ass’y - A4
A0967571 Operation Panel Board - 220/230V 1 23 17
A0961461 Operation Panel - LT
1 * 17
Correct A0961462 Operation Panel - A4
A0967571 Operation Panel Board - 220/230V 1 24 17

• UPDATE NO. 3 - STOPPER SPRING - To ensure the Side/End Fence positioning, the tension of
the Stopper Spring has been increased from 200gf to 1kgf.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA063379 AA066550 Stopper Spring - 22mm 2©2 1 43 27

UNITS AFFECTED:
Not available at time of publication.
BULLETIN NUMBER: 6645/6655/6665-026 REISSUE 02/09/95
APPLICABLE MODEL: FT6645/6655

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/66645 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/66645 Parts Catalog documentation.

• UPDATE NO. 1 - KEY COUNTER COMPONENT PARTS - As per request from the field, the Key
Counter Component parts have been registered as service parts.

Key Counter Jumper Connector

Slider Lock Stopped Screw

Key Counter Harness
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0965464 Key Counter Jumper Connector 0 1 12 53*
52161859 Stopped Screw - Slider Lock 0 1 12 54 *
A5095100 Key Counter Harness 0 1 12 55 *
* DENOTES NEW ITEM

* Operation Panel

• UPDATE NO. 2 - OPERATION PANEL -

Please correct your parts
catalog as follows:
#24

#23
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665-026
Page 2 of 2

Part Number Description Quantity Parts Catalog

Index No. Page

A0961461 Operation Panel Ass’y - LT

1 * 17
Incorrect A0961462 Operation Panel Ass’y - A4
A0967571 Operation Panel Board - 220/230V 1 23 17
A0961461 Operation Panel - LT
1 * 17
Correct A0961462 Operation Panel - A4
A0967571 Operation Panel Board - 220/230V 1 24 17

• UPDATE NO. 3 - STOPPER SPRING - To ensure the Side/End Fence positioning, the tension of
the Stopper Spring has been increased from 200gf to 1kgf.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA063379 AA066550 Stopper Spring - 22mm 2 2 1 43 27

UNITS AFFECTED:
Not available at time of publication.
BULLETIN NUMBER: 6645/6655/6665-027 09/30/94
APPLICABLE MODEL: FT6655/6665/6665

SUBJECT: SC508

SYMPTOM:
Even though paper exists in the right tray, the machine mis-detects a paper end condition and starts to
transport the paper from the left tray to the right. The result is an SC508.

[A]

CAUSE:
When loading the right tray, the operator did not set the
paper flush against the right side plate [A]. The rear
fences [B] cannot hold the paper correctly when the tray
bottom plate [C] rises and the paper slides down to the
left. If this occurs, the pick-up roller [D] may not touch
[B]
the paper and the machine mis-detects a paper end
condition. The left tray then moves toward the right [E]
resulting in the SC508 condition.

[B]

[D]
[B]

[E]

[C]

SOLUTION:
Instruct the operator to properly position the paper flush against the right side plate [A].
BULLETIN NUMBER: 6645/6655/6665-028 11/08/94
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 4-60 Updated Information

BULLETIN NUMBER: 6645/6655/6665-029 11/08/94
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PAPER VOLUME SENSOR SHORT CIRCUIT

SYMPTOM:
Short Circuit between the Paper Volume Sensor and Paper Volume Sensor Bracket.

CAUSE:
Configuration of existing Paper Volume Sensor and Bracket.

SOLUTION:
An Insulating Sheet has been added and the Sensor Bracket has been changed as shown below.

Insulating Sheet

Sensor Bracket

Old New

NOTE: The part number for the Sensor

Bracket has not changed.

REFERENCE
OLD PART NEW PART DESCRIPTION QTY PAGE ITEM
NO. NO.
A0966691 Sensor Bracket (FT6655/6665) 1 87 6
A0966178 Insulating Sheet 0 2 (FT6655/6665)
85 16 *
0 3 (FT6645)
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers with Serial Number A3354450257 and A3364450002 respectively and all FT6665
copiers (from first production) will have the new style Sensor Bracket and Insulating Sheet installed during
production.
BULLETIN NUMBER: 6645/6655/6665-030 11/08/94
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

• UPDATE NO. 1 - STOPPER SPRING - To ensure proper positioning of the side and end fences,
the Stopper Springs have been lengthened from 22mm to 24mm.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA066550 Stopper Spring - 22mm
2 1 43 26
AA066551 Stopper Spring - 24mm

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354450482 and A3364460002 respectively
and all FT6665 copiers (from first production) will have the new style Stopper Spring installed during
production.
Upper Transport Guide

• UPDATE NO. 2 - ROLLER GUIDE MYLAR- The Roller

Guide Mylars have been added to Roller Guide Mylar
improve duplex paper feed reliability.

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AA150374 Roller Guide Mylar 0 3 77 44 *
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354460237 and A3364460002 respectively
and all FT6665 copiers (from first production) will have the new style Roller Guide Mylars installed during
production.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665-030
Page 2 of 4

Old

• UPDATE NO. 3 - DUPLEX POSITIONING ROLLER -

To prevent the pick-off belt from
coming off the track, the duplex
positioning roller has been changed
as shown.
Duplex Positioning Roller New

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AF031001 AF031028 Duplex Positioning Roller 1 1 1 73 23

UNITS AFFECTED:
FT6645/6655 copiers - Not available at time of publication.
All FT6665 copiers (from first production) will have the new style Duplex Positioning Roller installed during
production.

Old

• UPDATE NO. 4 - WIRE FIXING PLATE - To facilitate

manufacturing, the Wire Fixing
Plate has been mounted on the
Jogger Support Plate. The part #103
number for the Jogger Support Plate #11
remains the same because, until
now, it has not been available as a New
service part.
#11

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0964718 Wire Fixing Plate 2 0 77 10
1
A0964715 A0964715 Jogger Support Plate 2 2 77 11
04340080B Philips Tapping Screw - M4 X 8 n n-2 77 101
1
09514008B Philips Screw with Washer - M4 X 8 n n+2 77 103

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354460048 and A3364460002 respectively
and all FT6665 copiers (from first production) will have the new style Jogger Support Plate and Screws
installed during production.

Continued...
Tech Service Bulletin No. 6645/6655/6665-030
Page 3 of 4

• UPDATE NO. 5 - THERMISTOR - To facilitate cleaning, the Thermistor has been covered with a
mylar sheet as shown below. Also, the Thermistor Fixing Plate has been changed
to reduce the pressure applied to the Thermistor.

Old New Thermistor Cover Mylar

Thermistor Fixing Plate

Thermistor
Thermistor

Thermistor Cover Mylar

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0964211 A0964221 Thermistor 1 1 3 65 3
A0964224 Thermistor Fixing Plate 1 0 3 65 36
A0964209 Thermistor Cover Mylar 0 1 1 65 36

NOTE: The Old and New parts are interchangeable as a set.

UNITS AFFECTED:
Not available at time of publication.

Continued...
Tech Service Bulletin No. 6645/6655/6665-030
Page 4 of 4

• UPDATE NO. 6 - RIGHT / LEFT PAPER SET DECALS - To prevent improper placement of paper in
the tandem tray, two Paper Set Decals have been added as shown.

Left Decal Right Decal

Tandem Tray

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0966677 Decal - Right Paper Set 0 1 45 32 *
A0966678 Decal - Left Paper Set 0 1 47 29 *
* DENOTES NEW ITEM

UNITS AFFECTED:
FT6645 copiers - Not available at time of publication.
All FT6655/6665 copiers manufactured after Serial Number A3364460244 and A3374460001 respectively
will have the Paper Set Decals installed during production.
BULLETIN NUMBER: 6645/6655/6665-031 12/13/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: ELECTRICAL MALFUNCTION DUE TO ELECTRICAL NOISE

SYMPTOM:
1. The scanner overruns home position and hits the optic frame.

2. During a copy cycle, the exposure lamp turns off suddenly, the scanner stops and the copy paper stops
in the fusing unit. A partially black solid image sometimes appears on the copy paper because the
exposure lamp turns off during the copy process.

3. When the paper is removed from the fusing unit after the above mentioned (item #2), a paper jam
occurs and the selected copy modes are cleared.

4. The erase lamp turns on at the wrong time and in the wrong position resulting in partially void images.

CAUSE:
Normally, there is minor arcing between the transfer belt and the OPC drum. Periodically, electrical noise
which is caused by this arcing affects the 5V lines. This noise is transmitted to the main control board
resulting in an electrical malfunction. This occurs most often just after a new transfer belt is installed in the
machine, when the electrical resistance of the transfer belt is at its lowest level (after 100~200 copies, the
electrical resistance of the transfer belt stabilizes).

TEMPORARY COUNTERMEASURE:

Arcing occurs here

Four (4) Ferrite Cores (16070478) have been added (see Installation Procedure on page 2).

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354470001 and A3364460001 respectively
will have the Ferrite Cores installed during production.

ORDERING PROCEDURE:
Ricoh Corporation will automatically ship four (4) Ferrite Cores for use on 100% of all FT6645/6655 copiers
manufactured prior to Serial Number A3354470001 and A3364460001 respectively based on Ricoh’s
Equipment Shipped Records.

Continued...
Tech Service Bulletin No. 6645/6655/6665-031
Page 2 of 2

FERRITE CORE INSTALLATION PROCEDURE:

CN111

1. Remove the rear cover.

2. Install one (1) Ferrite Core (16070478) on the wiring harness of CN111 as shown above.

3. Lower the Main Control Board.

[C]
4. Place two cores between the main harness [A] and
the band [B].

5. Place the remaining core between the band [B] and

the connector [C]. [B]

NOTE:

After installing each Ferrite Core, try to slide it along the [B]
harness to ensure the core isn’t pinching any wires. If it
[A]
can be moved, it is installed correctly.

PERMANENT COUNTERMEASURE:
A thin copper layer will be added on the Main Control Board to absorb electrical noise.

UNITS AFFECTED:
Not available at time of publication.
BULLETIN NUMBER: 6645/6655/6665-031 REISSUE 02/09/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: ELECTRICAL MALFUNCTION DUE TO ELECTRICAL NOISE

SYMPTOM:
1. The scanner overruns home position and hits the optic frame.

2. During a copy cycle, the exposure lamp turns off suddenly, the scanner stops and the copy paper stops
in the fusing unit. A partially black solid image sometimes appears on the copy paper because the
exposure lamp turns off during the copy process.

3. When the paper is removed from the fusing unit after the above mentioned (item #2), a paper jam
occurs and the selected copy modes are cleared.

4. The erase lamp turns on at the wrong time and in the wrong position resulting in partially void images.

CAUSE:
Normally, there is minor arcing between the transfer belt and the OPC drum. Periodically, electrical noise
which is caused by this arcing affects the 5V lines. This noise is transmitted to the main control board
resulting in an electrical malfunction. This occurs most often just after a new transfer belt is installed in the
machine, when the electrical resistance of the transfer belt is at its lowest level (after 100~200 copies, the
electrical resistance of the transfer belt stabilizes).

Arcing occurs here

TEMPORARY COUNTERMEASURE:
Four (4) Ferrite Cores have been added (see Installation Procedure on page 2).
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
0 1 89 32 *
16070478 Ferrite Core - RISC - 5 - F
0 3 95 113 *
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354470001 and A3364460001 respectively
will have the Ferrite Cores installed during production. All FT6665 copiers have had the Ferrite Cores
installed from the first production.

ORDERING PROCEDURE:
Ricoh Corporation will automatically ship four (4) Ferrite Cores for use on 100% of all FT6645/6655 copiers
manufactured prior to Serial Number A3354470001 and A3364460001 respectively based on Ricoh’s
Equipment Shipped Records.

Continued...
Tech Service Bulletin No. 6645/6655/6665-031 REISSUE
Page 2 of 2
FERRITE CORE INSTALLATION PROCEDURE:

CN111

1. Remove the rear cover.

2. Install one (1) Ferrite Core on the wiring harness of CN111 as shown above.

3. Lower the Main Control Board.

4. Place two cores between the main harness [A] and the band [B].

5. Place the remaining core between the band [B] and [C]
the connector [C].

NOTE:

After installing each Ferrite Core, try to slide it along the

[B]
harness to ensure the core isn’t pinching any wires. If it can
be moved, it is installed correctly.

[B]

PERMANENT COUNTERMEASURE: [A]

The 240V version (European version) Main Control Board has been substituted for the 115V, United States
version. The 240V version Main Control Board has a double-coated copper layer to meet European
electrical magnetic compatability standards and has a greater tolerence against electrical noise. Therefore,
the Ferrite Cores added as a temporary countermeasure are not required when the 240V version Main
Control Board is used.
REFERENCE
OLD NEW DESCRIPTION QTY INT PAGE ITEM
PART NO. PART NO.
A0955112 Main Control Board - 115V (FT6645) 1 0 89 10
1
A0955117 Main Control Board - 240V (FT6645) 0 1 105 *

A0965112 Main Control Board - 115V (FT6655) 1 0 89 10

1
A0965117 Main Control Board - 240V (FT6655) 0 1 105 *

UNITS AFFECTED:
FT6645/6655 copier Serial Number production cut-ins are not available at time of publication.
BULLETIN NUMBER: 6645/6655/6665-032 12/13/94
APPLICABLE MODEL: FT6645/6655

SUBJECT: FUSING UNIT MODIFICATIONS

SYMPTOM 1:
SC code 541, 542, 543, 544, 545, 546, or 547 is indicated (these SC codes cannot be canceled by the
customer).

CAUSE 1:
If the customer pulls out the fusing unit roughly, the bracket [A] is gradually tilted and the fusing connector
gradually comes out of its socket. Finally, the poor connection causes a fusing control malfunction. The
SC code displayed depends on which terminal pins are not connected correctly.
These holes are not threaded

[A]

[B]

[A] [A]

[B] [B]

SOLUTION 1:
To prevent the bracket [A] from tilting, install the two Nuts (provided in the Fusing Unit Modification Kit - see
page 2) as shown.
[C]

Nut
[C]

[C]

Nut
Nut
Continued...
[B]
Tech Service Bulletin No. 6645/6655/6665-032
Page 2 of 2

SYMPTOM 2:
Fusing Unit is not secured in the copier (falls to the floor when pulled out by customer).

CAUSE 2:
If the customer frequently pulls out the Fusing Unit roughly, the Stopper [A] gradually bends upward. If the
customer pushes the lever [B] to the right and pulls the Fusing Unit out, it is possible for the Fusing Unit to
come off the rail and fall to the floor.

[A]

[B] [A] [A]

Fusing front cover

SOLUTION 2:
The shape and thickness of the stopper has been changed as shown below. Because the shape of the
Stopper has been changed, the Fusing Unit Front Cover has also been changed (part of the cover has been
cut away to prevent it from being touched by the Stopper).

Stopper

Old New

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354460068 and A3364460001 respectively
will have the new style Fusing Unit part modifications installed during production.

FUSING UNIT MODIFICATION KIT (A0969902):

A kit has been made available to correct the symptoms described in this bulletin. The Fusing Unit
Modification Kit (A0969902) contains the following items:

1) two "thumb screw" type Nuts

2) one Fusing Unit Stopper
3) one Fusing Unit Front Cover

ORDERING PROCEDURE:
Ricoh Corporation will automatically ship one Fusing Unit Modification Kit (A0969902) for use on 100% of all
FT6645/6655 copiers manufactured prior to Serial Number A3354460068 and A3364460001 respectively
based on Ricoh’s Equipment Shipped Records.
BULLETIN NUMBER: 6645/6655/6665-032 REISSUE 04/17/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: FUSING UNIT MODIFICATIONS

SYMPTOM 1:
SC code 541, 542, 543, 544, 545, 546, or 547 is indicated (these SC codes cannot be canceled by the
customer).

CAUSE 1:
If the customer pulls out the fusing unit roughly, the bracket [A] is gradually tilted and the fusing connector
gradually comes out of its socket. Finally, the poor connection causes a fusing control malfunction. The
SC code displayed depends on which terminal pins are not connected correctly.

These holes are not threaded

[A]
[A] [A]

[B]

[B] [B]

SOLUTION 1: Newly added screw

To prevent the bracket [A] from tilting, the Fusing Unit

Rail has been modified so that it can be connected to
the rear frame of the copier with a screw.
Old
Also, to avoid interference between the Fusing Unit
Release Lever and the Toner Bottle, the Fusing Lock
Lever has been modified.

Fusing Unit Rail New

Lock Lever Knob

Old New

NOTE: The Fusing Lock Lever Knob is now available as a service part

Continued...
Tech Service Bulletin No. 6645/6655/6665-032 REISSUE
Page 2 of 3

SYMPTOM 2:
Fusing Unit is not secured in the copier (falls to the floor when pulled out by customer).

CAUSE 2:
If the customer frequently pulls out the Fusing Unit roughly, the Stopper [A] gradually bends upward. If the
customer pushes the lever [B] to the right and pulls the Fusing Unit out, it is possible for the Fusing Unit to
come off the rail and fall to the floor.
Fusing front cover [A] [A]
[A] [B]

SOLUTION 2:
The shape and thickness of the stopper has been changed as shown. Because the shape of the Stopper
has been changed, the Fusing Unit Front Cover has also been changed. Part of the cover has been cut
away to prevent it from being touched by the Stopper.

Fusing Unit Stopper

Cut out

Old New Fusing Cover

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0964251 A0964249 Fusing Unit Rail 1 1 1 99 12
A0964272 A0964273 Fusing Unit Stopper 1 1 1 99 13
04340080B Philips Tapping Screw - M4 x 8 n n+1 99 110
A0964261 A0964260 Fusing Lock Lever 1 1 1 99 11
A0964263 Lock Lever Knob 0 1 99 29 *
04140082W Binding Self Tapping Screw - M4 x 8 n n+1 99 101
A0964003 A0964008 Fusing Unit - 115V (A095 / A096) 1 1 1 65 *
A0964005 A0964009 Fusing Unit - 220V (A095 / A096) 1 1 1 65 *
A0964151 A0964150 Fusing Cover 1 1 1 65 5
* DENOTES NEW ITEM

Continued...
Tech Service Bulletin No. 6645/655/6665-032 REISSUE
Page 3 of 3

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3354460068, A3364460001 and
A3374050213 respectively will have the new style Fusing Unit part modifications installed during production.

FUSING UNIT MODIFICATION KIT (A0969902):

A kit has been made available for units in the field to correct the symptoms described in this bulletin. The
Fusing Unit Modification Kit (A0969902) contains the following items:

1) two "thumb screw" type Nuts

2) one Fusing Unit Stopper
3) one Fusing Unit Front Cover

[C]

Nut
[C]

[C]

Nut
Nut

[B]

NOTE: To prevent the Fusing Unit Bracket from tilting, install the two (2) Nuts (contained in the Modification
Kit) as shown above.

ORDERING PROCEDURE:
Ricoh Corporation will automatically ship one Fusing Unit Modification Kit (A0969902) for use on 100% of all
FT6645/6655 copiers manufactured prior to Serial Number A3354460068 and A3364460001 respectively
based on Ricoh’s Equipment Shipped Records.
BULLETIN NUMBER: 6645/6655/6665-033 02/09/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PARTS CATALOG UPDATES

• UPDATE NO. 1 - THERMISTOR SPRING - To facilitate servicing, the inner diameter of the
Thermistor Spring has been changed from 4.0 ±0.2mm to 4.5 ±0.2mm. This
change will make installation of the Thermistor Spring onto the Transfer Bias
Roller easier.

The Thermistor Spring is now called the

Pressure Spring - 12mm

Transfer Bias Roller

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
G0134566 Thermistor Spring 1→0
1 63 11
AA063531 Pressure Spring - 12mm 0→1

UNITS AFFECTED:
All FT6665 copiers have had the Pressure Spring installed since first production. FT6645/6655 copier Serial
Number production cut-ins are not available at time of publication.

• UPDATE NO. 2 - Please correct your Parts Catalog as follows:

1. Parts Catalog Correction

REFERENCE
INCORRECT CORRECT DESCRIPTION PAGE ITEM
PART NO. PART NO.
Bushing - 4 x 5 81 110
07074050 07074050B
83 109

Continued...
Tech Service Bulletin No. 6645/6655/6665-033
Page 2 of 6

2. Please add the following parts to your Parts Catalog :

31

102

102

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
16061336 Capacitor - 10000PF 50V 1 105 173 *
A0965449 Grounding Wire 1 89 31 *
* DENOTES NEW ITEM
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AX520020 Exposure Lamp - 115V (A097) 1 27 6

Symbol Symbol
No. No.
Add to page 103
C300 172 *
* DENOTES NEW ITEM

3. Please eliminate the following parts from your Parts Catalog:

eliminate #10 and #12

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0961878 1st Mirror Support Plate 1 0 27 12
A0961879 1st Mirror Cushion 1 0 27 10

Continued...
Tech Service Bulletin No. 6645/6655/6665-033
Page 3 of 6
LCT Support Plate

• UPDATE NO. 3 - LCT SUPPORT PLATE - To insure

that 8 1/2 X 11 inch sideways paper
is loaded correctly, the LCT Support
Plate has been added to the End
Fence Rail as shown.

NOTE: If the customer needs to position 8 1/2 X 11 inch lengthwise paper, a service representative will have
to remove the LCT Support Plate
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0966759 LCT Support Plate 0 1 49 25 *
04340060B Philips Tapping Screw - M4 x 6 n n+2 49 101
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6665 copiers manufactured after Serial Number A3374050213 will have the LCT Support Plate
installed during production. FT6655 copier Serial Number production cut-ins are not available at time of
publication.

Paper Guide Seal

• UPDATE NO. 4 - PAPER GUIDE SEAL 2, 3 - When the

customer pulls out the tray to clear a misfeed, it
is possible for paper to drop behind the tray.
This can occur when the leading edge of the
paper stops between the feed roller and the
separation roller but has not reached the
vertical transport roller. To avoid this, the Paper
Guide Seal has been added as shown. The
function of the Seal is to catch the misfed
paper and to pull it out along with the tray.

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AA153005 Paper Guide Seal - 2 0 2 41 19 *
AA153004 Paper Guide Seal - 3 0 1 43 30 *
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6665 copiers manufactured after Serial Number A3554070001 and A3374050218 respectively
will have the Paper Guide Seal installed during production. FT6655 copier Serial Number production cut-ins
are not available at time of publication.

Continued...
Tech Service Bulletin No. 6645/6655/6665-033
Page 4 of 6

• UPDATE NO. 5 - LOWER FUSING EXIT ROLLER - If certain types of copy paper which contain a
lot of Calcium carbonate is used, the toner in half tone image areas will not be
completely fused onto the paper. The lower fusing exit roller picks up the unfused
toner particles and becomes contaminated. To prevent this, the shape of the lower
fusing exit roller has been changed as shown.
Old New

Lower Fusing Exit Roller

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AF021016 AF022084 Lower Fusing Exit Roller 2 2 1 67 17

UNITS AFFECTED:
All FT6645 copiers manufactured after Serial Number A3354070083 will have the new style Lower Fusing
Exit Roller installed during production. FT6655/6665 copier Serial Number production cut-ins are not
available at time of publication.

• UPDATE NO. 6 - Please correct your Parts Catalog as follows:

1. Correct the index number for the Upper Front Fixing Plate (page 96).

2. Eliminate the portion of the illustration highlighted by the dotted line below .

Change item #26 to #22 (Upper Fixing Plate)

22

Eliminate this portion of the illustration

Continued...
Tech Service Bulletin No. 6645/6655/6665-033
Page 5 of 6

3. Add the following part to the illustration on page 96 .

Stopper Bracket

4. Correct the following part number and description as shown below .

REFERENCE
INCORRECT CORRECT DESCRIPTION QTY PAGE ITEM
PART NO. PART NO.
09653010W Tapping Screw with Flat Washer - M3 x 1 n 47 107
09653008W Tapping Screw with Flat Washer - M3 x 8 n 47 107

5. The Circuit Breaker mentioned on page 91 (item #106) is that for the 115V machine. The Circuit
Breaker used for the 220V machine is a different type. Please correct your Parts Catalog as
follows:
REFERENCE
INCORRECT CORRECT DESCRIPTION QTY PAGE ITEM
PART NO. PART NO.
11070693 Circuit Breaker - 18A 250V 1 91 106
11070693 Circuit Breaker - 18A (115V) 1
91 106
11070473 Circuit Breaker - 18A (220V) 1

Continued...
Tech Service Bulletin No. 6645/6655/6665-033
Page 6 of 6

• UPDATE NO. 7 - STOPPER BRACKET - To prevent deformation of the stopper bracket (shown
above), the thickness of the bracket has been changed from 1.6mm to 2.9mm.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0966818 A0966819 Stopper Bracket 1 1 1 97 26

NOTE: If the stopper bracket is deformed, the built in large capacity tray (1.5K LCT) the tray connector
gradually comes out of the socket. The poor connection results in a defective dc motor (1.5K LCT).

UNITS AFFECTED:
FT6655/6665 copier Serial Number production cut-ins are not available at time of publication.

• UPDATE NO. 8 - CLEANER CUSHION - To ensure the return movement of the corona wire
cleaner, the material of the Cleaner Cushion has been changed.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA161034 AA161105 Cleaner Cushion 1 1 1 59 42

UNITS AFFECTED:
All FT6645 copiers manufactured after Serial Number A3354070001 will have the new style Cleaner
Cushions installed during production. FT6655/6665 copier Serial Number production cut-ins are not
available at time of publication.
BULLETIN NUMBER: 6645/6655/6665-034 02/17/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: SOFTWARE MODIFICATION

GENERAL:
The Main Control Board ROMs (A0965151 and A0965153) have been upgraded to version "B".

CAUTION: Whenever upgrading the old Main Control Board ROMs to the new version ROMs in the
field, you MUST also perform the mechanical modification described on page 3 (see
UPDATE NO. 7 - BUILT-IN LCT LIFT MOTOR CONTROL MODIFICATION). Replacing the
ROMs without performing this modification might lock the built-in LCT so that it cannot
open. This is because the bottom plate stops at a slightly higher position due to the
motor’s quicker response.

The modifications to the new software are as follows:

• UPDATE NO. 1 - MACHINE ENTERS THE SCREEN SAVER MODE DURING AUTO COUNTING
If the machine enters the Screen Saver Mode while performing original Auto
Count, after counting all the originals, the machine indicates an original misfeed.

Countermeasure - The machine does not enter the Screen Saver Mode while Auto Counting
originals.

• UPDATE NO. 2 - OPERATING TIME INDICATION IS INCORRECT

During normal operation, the time remaining before the end of the copy job is
indicated by animation on the touch panel screen. However, during duplex mode
when using the RDH and Finisher, the indicated time was incorrect.

Countermeasure - For Single Side Original to Duplex Copy Mode, it is impossible to calculate the
time due to the complex operation using the alternate feed system. Therefore, in
this mode, the operating time is not indicated.
For Duplex Original to Duplex Copy Mode, the accuracy of the indicated operation
time has been improved.

• UPDATE NO. 3 - THE RDH/FINISHER MAXIMUM COPY SET LIMITATION IS 50 SETS

If a number larger than 50 was entered, it was canceled and "50" was displayed.

Countermeasure - When using the RDH and Finisher, the selectable copy set for sort mode has
been changed to "999" (In the sort mode, due to the alternate feed operation, the
paper stacked in the duplex tray is always less than 50 sheets).

Continued...
Tech Service Bulletin No. 6645/6655/6665-034
Page 2 of 4

• UPDATE NO. 4 - COPIER MISFEED INDICATION CAUSED BY AN RDH ORIGINAL MISFEED

This symptom occurs depending on the copy tray selected and the size of the
copy paper (the combination of the longer paper path and shorter paper length
tends to create this symptom).

Countermeasure - In the event of an RDH original exit misfeed, the copier exits all copy paper from
the machine and displays an original misfeed.

• UPDATE NO. 5 - ST24 SORTER STAPLER INCORRECT STACK LIMITATION (FT6645 ONLY)
In Front Cover Mode, the maximum sorter capacity was 15 sheets/bin regardless
of the paper size used.

Countermeasure - The maximum sorter capacity in the Sort Mode is as follows:

A4, 8 1/2"x11"
B4, 8 1/2"x14" or larger: 15 sheets/bin

• UPDATE NO. 6 - JOB RECOVERY IN COVER SHEET MODE

Normally, after a paper misfeed occurs and is cleared by following the job
recovery instructions, the machine restarts copying. However, when using Cover
Sheet Mode (either "2 in 1 Mode" or "Duplex Copy Mode"), the copy job is
completed on copy paper fed from the Cover Sheet tray (in Cover Sheet Mode,
cover sheets should be placed only at the top and the bottom of a copy set).

Countermeasure - When using Cover Sheet Modes, cover sheets are placed only at the top and the
bottom of a copy set. After a paper misfeed occurs and is cleared by following the
job recovery instructions, the machine restarts copying from the correct paper tray.

• UPDATE NO. 7 - BUILT-IN LCT LIFT MOTOR CONTROL MODIFICATION (FT6655/6665 ONLY)
To improve the accuracy of the LCT paper bottom plate stop position, the paper
lift motor control has been modified. As a result of this modification, the bottom
plate is stopped immediately when the motor is turned off (this helps reduce the
occurrence of SC504).
Because the motor stop timing of the bottom plate has been changed (via the new
software), two mechanical modifications are required to slightly lower the bottom
plate stop position. Please refer to the next page for the mechanical field
modification installation procedure.

Continued...
Tech Service Bulletin No. 6645/6655/6665-034
Page 3 of 4

FT6655/6665 MECHANICAL FIELD MODIFICATION INSTALLATION PROCEDURE

CAUTION: Whenever upgrading the old Main Control Board ROMs to the new version ROMs in the
field, the following modification is MANDATORY. Replacing the ROMs without this
modification might lock the built-in LCT so that it cannot open. This is because the
bottom plate stops at a slightly higher position due to the motor’s quicker response.

1. Remove the third tray (built-in LCT) (4 screws).

2. Remove the Lower Sensor Bracket [A] (A0966789)

(1 screw) and remove the Original Sensor [B] from the
bracket.
Third Tray (built-in LCT)
3. Install the Original Sensor [B] onto the new style
Lower Sensor Bracket (A0966790) and install the new [B]
style Lower Sensor Bracket (1 screw).
[A]
This positions the sensor 2mm lower.

4. Remove the Side Fences [C] (1 screw each).

less than
5. Remove the Tray Bottom Plate [D] (4 screws). [C] 0.3mm
[D]
[C]

6. After cleaning the bracket surface [E], adhere the Lower

Sensor Actuator Extension [F] as illustrated.
0 ± 5mm

This increases the length of the actuator by 1.5mm.

NOTE: After these modifications, the LCT lock release position

[E]
is 3.5mm lower than before.
[F]

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3355420001, A3365420313 and
A3375420001 respectively will have the B version ROMs and built-in LCT modifications installed during
production.

ORDERING PROCEDURE:
To obtain the new version ROMs (ROM Kit P/N A096F400B), new style Lower Sensor Bracket and Lower
Sensor Actuator Extension (Hardware Kit P/N A0969515) at no charge, please complete the form on page 4
and fax it to Technical Services .

Continued...
Tech Service Bulletin No. 6645/6655/6665-034
Page 4 of 4

SUBJECT: FT6645/6655/6665 MAIN CONTROL BOARD ROMS

FT6655/6665 MECHANICAL FIELD MODIFICATION
Fax this entire page in "DETAIL" mode, ATTN: Technical Services - Copier Fax Number: 201-882-3960.

Each FT6645/6655/6665 Serial Number given will represent a request for one ROM Kit (A096F400B). In a ddition to the
the ROM Kit, each FT6655/6665 Serial Number given will also receive one Hardware Kit (A0969515). The Hardware Kit
consists of one new style Lower Sensor Bracket and one Lower Sensor Actuator Extension (see page 3 o f this bulletin
for details).

NOTE: The FT6645 does not require the Hardware Kit as it does not have a built-in LCT.

Serial Number (s)

FT6645 FT6655 FT6665
1
2
3
4
5
All serial number information will be verified before shipment is made.

NOTE Old ROMs must be returned within five (5) days to:

Ricoh Corporation
146-148 Sound Beach Avenue
Old Greenwich, CT 06870

CAUTION: Whenever upgrading the old Main Control Board ROMs to the new version ROMs in the
field, you MUST also perform the mechanical modification described on page 3
(FT6655/6665 only). Replacing the ROMs without this modification might lock the
built-in LCT so that it cannot open. This is because the bottom plate stops at a slightly
higher position due to the motor’s quicker response.

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3355420001, A3365420313 and
A3375420001 respectively will have the B version ROMs and built-in LCT modifications installed during
production.

PLEASE TYPE OR PRINT CLEARLY.

DEALER NAME:
ADDRESS:
CITY: STATE: ZIP CODE:
ATTENTION: PHONE # :
DEALER ACCOUNT NUMBER:
BULLETIN NUMBER: 6645/6655/6665-035 02/17/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• table of contents vii Updated information

• 6-43 Additional Information

BULLETIN NUMBER: 6645/6655/6665-036 03/13/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: DUPLEX PAPER END SENSOR FEELER BREAKAGE

SYMPTOM:
The customer pulls out the Duplex Unit and the Duplex Paper End Sensor Feeler breaks off. The machine
then displays "Paper in Duplex" even though there is no paper present in the Duplex Tray.

CAUSE:
1. The Duplex Entrance Sensor Bracket [A] is too close to the Entrance Sensor Feeler [B]. This causes
the Entrance Transport Assembly to remain down even if the front door of the machine is open. When
this condition exists, pulling out the Duplex Unit will break the Duplex Paper End Sensor Feeler.

2. The Arm Release Spring [C] has insufficient tension to raise the Duplex Entrance Assembly when the
copier front door is opened. When this condition exists, pulling out the Duplex Unit will break the Duplex
Paper End Sensor Feeler.

[A]

View with Fusing Unit removed

[B]
[D]

[C]

FIELD COUNTERMEASURE:

1. Re-form the sensor bracket [D] toward the right slightly (3 ~ 5mm).

2. Re-form the upper position of the spring [C] to increase spring tension.

Continued...
Tech Service Bulletin No. 6645/6655/6665-036
Page 2 of 2

PRODUCTION COUNTERMEASURE:
The Arm Release Spring (AA066224) has been changed so that the spring tension is increased.

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A335543XXXX, A336543XXXX and
A337543XXXX respectively will have the new style Arm Release Spring installed during production.
BULLETIN NUMBER: 6645/6655/6665-037 03/13/95
APPLICABLE MODEL: FT6645/6655

SUBJECT: SERVICE CODE 507

SYMPTOM:
At installation or shortly thereafter, SC507 is displayed.

CAUSE:
It has been determined that if the connector between the mainframe and the LCT is connected while the
main switch of the mainframe is turned "ON" the IC on the Motor Control Board which controls the Paper
Feed Motor is destroyed.

Depending on the extent of the damage to the IC, prior to displaying SC507, one or more of the following
symptoms may be observed:

• Paper Feed Motor hesitation

• Skew

• Varying registration

SOLUTION:
DO NOT connect the LCT Harness to the mainframe while the main switch is turned "ON".
BULLETIN NUMBER: 6645/6655/6665-038 04/17/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: VERTICAL BLACK LINES ON COPIES / SCRATCHED DRUM

SYMPTOM:
Carrier (developer) scratches the OPC drum resulting in vertical black lines on copies.

Carrier
CAUSE:
OPC Drum
Occasionally, a few carrier particles adhere to the OPC drum and
are collected by the cleaning unit. This does not affect the drum
and is considered normal operation. However, very rarely, carrier
particles pass through the cleaning unit and are caught by the
development unit entrance seal where they are pressed against
the OPC drum as shown. If the machine runs in this condition for Developer
Pressure
a long time, the carrier may scratch the OPC surface resulting in
vertical black lines on copies.

FIELD COUNTERMEASURE:
To reduce the pressure applied to the carrier, the Entrance Seal
has been modified as shown. Because of the unique
shape of the new style Entrance Seal, it absorbs the
fluctuating (excess) pressure of the developer so that Old New
there is not enough pressure to scratch the OPC
surface.

Entrance Seal Entrance Seal

NOTE: Refer to the Field Service Manual, page 5-43,
for the Entrance Seal replacement procedure.
OPC Drum OPC Drum

UNITS AFFECTED:
All FT6645/6655 copiers manufactured prior to Serial Number A3354470106 and A3364470002 respectively
are susceptible to the above mentioned symptom.

ORDERING PROCEDURE:
Ricoh Corporation will automatically ship one new style Entrance Seal (A0963098) at no charge for use on
100% of all FT6645/6655 copiers manufactured prior to Serial Number A3354470106 and A3364470002
respectively (see Temporary Field Countermeasure, page 2) based on Ricoh’s Equipment Shipped Records.

Continued...
Tech Service Bulletin No. 6645/6655/6665-038
Page 2 of 2

TEMPORARY PRODUCTION COUNTERMEASURE:

To reduce the pressure placed on the entrance seal, the amount of developer around the upper development
roller has been strictly controlled by adjusting the doctor gap to the narrower limit of the specification.

CAUTION: As mentioned in the Field Service Manual, never adjust the doctor gap in the field.

UNITS AFFECTED:
All FT6645/6655 copiers manufactured after Serial Number A3354470106 and A3364470002 respectively
and all FT6665 copiers from first production have had the doctor gap adjusted to the narrower specification
during production.

PERMANENT PRODUCTION COUNTERMEASURE:

The new style Entrance Seal described in the FIELD COUNTERMEASURE on Page 1 has been applied to
the production machines.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963100 A0963098 Entrance Seal 1 1 1 53 4

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3355410144, A3365410084 and
A3375410001 respectively will have the new style Entrance Seal installed during production.
BULLETIN NUMBER: 6645/6655/6665-039 04/17/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

• UPDATE NO. 1 - JOGGER UNIT - To improve the positioning of the Jogger Fence and to prevent
the Lower Transport Guide from warping, the following modifications have been
made:
Rear Jogger Fence
Mylar
• Mylar has been added to the rear of the Jogger
Fence as shown. This reduces the variation of the
Jogger Fence stop positioning.

17.8 ± 0.2 mm
• The Roller Holder Bracket has been made more
durable to prevent the Lower Transport Guide from
Lower Transport Guide
warping. Because of this modification, the shape of
the Lower Transport Guide has been changed slightly.

Roller Holder Bracket

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0964760 A0964763 Rear Jogger Fence 1 1 1 73 17
AA150362 Mylar 0 1 73 43 *
A0964926 A0964938 Roller Holder Bracket 1 1 "1" AS 75 42
A0964927 A0964939 Lower Transport Guide 1 1 A SET 75 29
04140082B Binding Self Tapping Screw - M4x8 n n+4 75 102
* DENOTES NEW ITEM

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665-039
Page 2 of 3

UNITS AFFECTED:
All FT6645 copiers manufactured after Serial Number A3554070001 will have the new style Roller Holder
Bracket and Mylar installed during production. FT6655/6665 Serial Number cut-ins not available at time of
publication.

• UPDATE NO. 2 - FRONT RUBBER SEAL - To prevent toner contamination on the front edge of the
Transfer Belt, the Rubber Seal has been added.

Belt Cleaning Blade

Front Rubber Seal

Cleaning Blade Stay

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0963940 Front Rubber Seal 1 63 45 *
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655/6665 copiers will utilize the new style Roller Holder Bracket and Mylar as service parts only.

• UPDATE NO. 3 - GROUNDING WIRE - To reduce electrical noise, the grounding wire, shown
below, has been added.

Grounding Wire

Continued...
Tech Service Bulletin No. 6645/6655/6665-039
Page 3 of 3

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0965448 Grounding Wire 0 1 61 57 *
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6665 copiers manufactured after Serial Number A3374050213 will have the Grounding Wire installed
during production. FT6645/6655 Seial Number cut-ins not available at time of publication.

• UPDATE NO. 4 - PARTS CATALOG CORRECTION - Please correct your Parts Catalog as follows:

REFERENCE
INCORRECT CORRECT DESCRIPTION PAGE ITEM
PART NO. PART NO.
A0964487
Upper Exit Guide 69 8
A0964478
A0975140
Optics Control Board (FT6665) 89 1
A0975150
A0965441 Drum Unit Harness 95 18
A0965441 Drum Unit Harness (FT6645 / FT6655)
95 18
A0975441 Drum Unit Harness (FT6665)
BULLETIN NUMBER: 6645/6655/6665-040 04/05/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: SHORT BLACK LINES ON DRUM (MEDAKA)

SYMPTOM:
Short black lines appear on the drum surface.

CAUSE:
Certain additives contained in particular varieties of copy paper cause toner to stick to the drum. This occurs
most often when the copier is operated in a warm environment, for example, when the room temperature is
high, or when the copy volume is high (especially when duplex copying).

SOLUTION:
To increase drum cleaning efficiency, a new style cleaning brush has been developed for use with machines
exhibiting the above mentioned symptom. The new style brush (A0969523) contains fewer bristles, however,
the diameter of the bristles has been increased.

NOTE: The new style Cleaning Brush should be used only for units exhibiting the above mentioned
symptom as use of this brush may decrease the life of the drum.

ORDERING PROCEDURE:
The new style Cleaning Brush (A0969523) can be obtained through normal NSPC channels.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 040 RESSIUED H 06/13/97

APPLICABLE MODEL: FT6645/6655/6665

n COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SHORT BLACK LINES ON DRUM (MEDAKA)

for reproduction of additional bulletins.

SYMPTOM:

q MECHANICAL
Short black lines appear on the drum surface.

CAUSE:
Additives contained in particular varieties of copy paper cause toner to stick to the drum. This occurs most
often when the copier is operated in a warm environment, for example, when the room temperature is high,

q
or when the copy volume is high (especially when duplex copying).

ELECTRICAL
H SOLUTION:
To increase drum cleaning efficiency, a new style Cleaning Brush has been developed for use with machines
exhibiting the above mentioned symptom. The new style Cleaning Brush (AD042032) contains fewer

q
bristles, however, the diameter of the bristles have been increased. When installing the new Cleaning Brush

PAPER PATH
the developer should also be replaced because the paper dust in the developer may cause Medaka.
Replacing the drum may also be necessary, because, it may be difficult to completely remove all the
adhered toner from the drum surface.

q
n
q SMPARTS
OTHER
BULLETIN NUMBER: 6645/6655/6665-041 05/12/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: RUST ON FEED CLUTCH FACE-PLATE

SYMPTOM:
"Z-fold" paper misfeed in section C when feeding from internal paper trays (feed stations 1, 2 or 3).

CAUSE:
The paper Feed Clutches (AX210037) have a build-up of rust on the face-plate. This causes improper paper
feed.

FIELD COUNTERMEASURE:
1. Clean the clutch surface with 600 grit emery cloth.
Rinse the clutch surface with alcohol.
Clean the clutch with a dry cloth.
Apply a small amount of lightweight oil (non-Teflon) to the clutch face-plate.
Wipe off excess oil, reassemble clutch.

2. Replace the Feed Clutch (AX210037).

PRODUCTION COUNTERMEASURE:
The following measures have been taken to prevent the formation of rust on the Feed Clutches during and
after the manufacturing process:

1. The material used in the washing process has been changed from water to oil.

2. To prevent perspiration from contacting the clutch, rubber gloves are now used.

3. While the clutches are in inventory, they are now placed in plastic boxes and covered with a rust
preventative paper.

4. Rust preventative paper has been placed between the clutch housing and the disk.

UNITS AFFECTED:
The preventative measures described above have been implemented since the December, 1994 clutch
production run.
BULLETIN NUMBER: 6645/6655/6665-042 05/12/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: INOPERATIVE PRINT, CLEAR MODES and/or CLEAR/STOP KEY(S)

SYMPTOM:
The Print, Clear Modes and/or Clear/Stop key(s) does not respond when pressed.

CAUSE:
Poor solder joints at the switches corresponding to the above mentioned key(s) on the Key
Board (A0961517).

NOTE: When this condition exists, the customer may repeatedly push the keys resulting in damage to the
Operation Panel PCB.

FIELD COUNTERMEASURE:
Re-solder the affected switches on the Operation Panel PCB.

PRODUCTION COUNTERMEASURE:
The amount of solder used has been strictly controlled since March, 1995 production.
BULLETIN NUMBER: 6645/6655/6665-043 05/12/95
APPLICABLE MODEL: FT6645/6655/6665

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

• UPDATE NO. 1 - To ensure the collection of used toner, the agitator and its drive mechanism have
been added.
Toner Collection Case Assembly

110

24

110
111
110 25
26
24
27

Registration Drive Unit 40

39
33

41

47 42
105 107
109
113
43 109
107
107
107
45 46
44 44

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665-043
Page 2 of 3

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM
A0963680 Toner Collection Case Assembly 0 1 79 23 *
AA080198 Bushing - 6 x 10 x 4 0 2 79 24 *
A0963689 Agitator Plate 0 1 79 25 *
AA143717 Agitator Shaft 0 1 79 26 *
AB015012 Gear - 12Z 0 1 79 27 *
09603006W Philips Flange Screw - M3 x 6 0 1 79 111 *
07200040B Retaining Ring - M4 n n+3 79 110
AA145203 AA148440 Registration Drive Shaft 1 1 81 33
AB030458 Pulley - 28Z 0 1 81 47 *
07200060B Retaining Ring - M6 n n-1 81 105
07200040B Retaining Ring - M4 n n+4 81 107
A0961127 Registration Drive Unit 0 1 81 48 *
AB030392 Pulley - 18Z 0 1 81 39 *
AA043404 Timing Belt - 266P2M4 0 1 81 40 *
AA066220 Tension Spring 0 1 81 41 *
A0961136 Tightener 0 1 81 42 *
AA145799 Drive Shaft 0 1 81 43 *
AA080198 Bushing - 6 x 10 x 4 0 2 81 44 *
A0961174 Drive Support Bracket 0 1 81 45 *
AB015012 Gear - 12Z 0 1 81 46 *
08073005 Washer - Reverse Gear 0 1 81 113 *
04340080B Philips Tapping Screw - M4 x 8 n n+2 81 109
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
Fusing Unit Guide Lever

• UPDATE NO. 2 - To facilitate manufacturing, the

method used to fix the Fusing Unit
Guide Lever to the Left Door has
been changed to the screw type
Added Screws
shown to the right.

Continued...
Tech Service Bulletin No. 6645/6655/6665-043
Page 3 of 3

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0961303 Fusing Unit Guide Lever 0 1 13 60 *
08025124 Tapping Screw - M3 x 8 n n+2 13 112 *
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 3 - To ensure connection between the male and

female AC Connectors, the tension of the
Connector Spring has been increased. AC Connector

Also, to prevent a poor connection caused by an over adjustment for side-to-side

registration of the 1.5K LCT, a screw hole on the LCT stopper has been shortened
as shown in the illustration below.

10 7mm

NOTE: The same Stopper is used on the Tandem Tray.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA063259 AA063286 Connector Spring 2 2 1 91 17
A0966669 A0966697 LCT Stopper 2 2 1 49 16

UNITS AFFECTED:
Not available at time of publication.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 044 06/16/95

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

for reproduction of additional bulletins.

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

MECHANICAL
• UPDATE NO. 1 - GEAR-24Z - To ensure Transfer Belt Drive, the following modifications have been
applied:

1. The size of both the Belt Drive Shaft and Pulley have been changed to ensure the pulley is securely
press-fitted on the shaft.

2. To prevent the 24Z Gear from turning freely on the shaft, both the shaft and Gear have been

ELECTRICAL
changed to D-shape as shown below.

Pulley
Old New

PAPER PATH
Gear - 24Z
Belt Drive Shaft

FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AB013770 AB013984 Gear - 24Z 1 1 1 81 35
A0961125 A0961126 Belt Drive Shaft 1 1 1 81 36 PARTS

UNITS AFFECTED:
Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
OTHER

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 044
Page 2 of 2

•UPDATE NO. 2 - RELEASE ARM - The material of the Release Arm has been changed from
aluminum to iron to prevent it from becoming deformed. This will prevent the poor
image transfer associated with a bent Release Arm.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963658 A0963959 Relase Arm 1 1 1 99 19

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 3 - LEFT SCALE - With use, the Left Scale may warp slightly. This may allow
originals to go between the Left Scale and the Exposure Glass when they are
switched back. As a countermeasure, the material of the Left Scale has been
changed from ABS to Polycarbonate and the grooves on the back side have
been removed.

New
Old

Grooves

(Back side view)

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961904 A0971736 Left Scale - LT 1 1 1 19 1
A0961901 A0971731 Left Scale - A4 1 1 1 19 1

UNITS AFFECTED:
Aluminum Insert
Not available at time of publication.

• UPDATE NO. 4 - BELT UNIT KNOB - If the Belt Unit

Knob is rotated excessively when
1.0 → 2.5mm

releasing the Belt Unit, the knob may

break at the flat portion of the
aluminum insert. To prevent this, the
flat area has been modified as A View at A
shown to the right.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963961 A0963960 Belt Unit Knob 1 1 0 99 16

UNITS AFFECTED:
Not available at time of publication.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 045 06/16/95

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SC508
for reproduction of additional bulletins.

SYMPTOM:
SC508

MECHANICAL
CAUSE:
Broken connection at the black wire to the Tandem Tray Motor occurring during the assembly process.

ELECTRICAL
FIELD COUNTERMEASURE:
Inspect and resolder the broken lead to the motor.

PRODUCTION COUNTERMEASURE:

PAPER PATH
To prevent this problem, the direction the wire is attached and the soldering method used have been
changed.

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured prior to May, 1995 may exhibit this symptom.

FSM
PARTS
OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 046 08/16/95

APPLICABLE MODEL: FT6645/6655/6665
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
for reproduction of additional bulletins.

The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

• UPDATE NO. 1 - TRANSFER BELT SOLENOID, ETC... - To ensure the Transfer Belt is lifted high
enough, a stronger solenoid has been employed. Because the new solenoid is
larger than the old one, the Solenoid Bracket and Transfer Belt Casing have been
changed.

Solenoid Bracket

64 → 84mm Transfer Belt Solenoid

Old New

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963911 A0963921 Transfer Belt Solenoid 1 1 3/S 63 22
A0963918 A0963922 Solenoid Bracket 1 1 3/S 63 23
A0963901 A0963924 Transfer Belt Casing 1 1 3/S 63 32

UNITS AFFECTED:
Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued
Tech Service Bulletin No. 6645/6655/6665 - 046
Page 2 of 2

• UPDATE NO. 2 - ARM RELEASE SPRING - To ensure

that the Paper Guide properly moves
to the top position, the Arm Release
Spring has been changed to a
stronger type.

Arm Release Spring

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA066224 AA066275 Arm Release Spring 1 1 1 93 2

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 3 - PARTS CATALOG CORRECTION - Correct your Parts Catalog as follows:

Grounding Plate

# 11 LCD Display Sheet

REFERENCE
PART NUMBER DESCRIPTION ITEM PAGE
INCORRECT CORRECT
A0961508 Grounding Plate 11 16 17
A0961513 LCD Display Sheet 16 11 * 17
* PART ILLUSTRATION MISSING FROM PAGE 16
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 047 08/16/95

APPLICABLE MODEL: FT6645/6655/6665
Note: This copy intended as master of original

SUBJECT: FIELD SERVICE MANUAL - INSERT

GENERAL:
for reproduction of additional bulletins.

The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 2 sets of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 4-58 Additional Information PM Table Addition

• 4-59 Additional Information PM Table Addition
• 4-64 Additional Information PM Procedure Addition
• 4-67 Additional Information PM Procedure Addition
• 4-69 Additional Information PM Procedure Addition
• 4-70 Additional Information PM Procedure Addition
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 048 10/11/95

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
for reproduction of additional bulletins.

The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

MECHANICAL
• UPDATE NO. 1 - DRIVE SHAFT- Correct the illustration on page 82 and the part
number/description on page 83 of the Parts Catalog as shown below.

ELECTRICAL
Incorrect Correct

Upper Drive Shaft Lower Drive Shaft

(AA145212) (AA145212)

PAPER PATH
FSM
PARTS

REFERENCE
INCORRECT CORRECT DESCRIPTION QTY INT PAGE ITEM
PART NO. PART NO.
AA145212 Upper Drive Shaft
OTHER

1 1 1 83 26
AA145211 Lower Drive Shaft

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 048
Page 2 of 2

• UPDATE NO. 2 - OPERATION PANEL BOARD - The Operation Panel Board (item #23) is not
included in the Operation Panel (A0961461) assembly. If you need to replace the
entire Operation Panel, you must also order the Operation Panel Board
(A0967560) separately. This is because item #23 is different for each market the
machine is sold in. Also, add the part number and description for the Sheet, item
#25 to your Parts Catalog.

Add the Sheet (item #25)

to your Parts Catalog

Item #23 is not included in the

Operation Panel assembly

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM

A0961505 Sheet 0 1 17 25
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 049 12/22/95

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
for reproduction of additional bulletins.

The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing Parts Catalog documentation.
Paper Tray Stopper

MECHANICAL
Rear Plate Rear Plate
Paper Tray Cushion
• UPDATE NO. 1 - PAPER END STOPPER, ETC... - For more
accurate side to side registration, the tray
stop position is now determined at the feed
roller side (right) rather than at the paper
trail edge side (left).
Old New

ELECTRICAL
The shape of the Paper End Feeler (shown below) has been changed so that the
feeler is pushed up by the paper more securely when the paper tray slides in.
Also, the Paper Flattener on the front side has been changed to prevent the
paper from being caught when the paper tray is pulled out. The Middle Guide
Plate (not shown) has been reinforced to prevent it from being deformed.

Old New Old New

Paper End Feeler Paper Flattener

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

FSM
A0966283 Cushion - Rear Plate 0➝1 100 41*
A0966174 A0966158 Paper Tray Stopper 2➝2 3 87 19
A0966190 A0966191 Middle Guide Plate 1➝1 0 101 34
A0966342 A0966362 Paper End Feeler 3➝3 1 39 9
PARTS

A0966360 Paper Flattener 6➝3 39 23

A0966363 Paper Flattener 0➝3 1 39 62*
* DENOTES NEW ITEM
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
OTHER

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 049
Page 2 of 4

UNITS AFFECTED:
All FT6655 copiers manufactured after Serial Number A3365080219 will have the new style parts described
in Update No. 1 installed during production. FT6645/6665 Serial Number information was not available at
time of publication.

• UPDATE NO. 2 - GRIP COVER - Due to part standardization, the front cover grip area has been
changed as shown. The new type has a self-tension structure which has
eliminated the grip spring of the old type.
Old New

Grip Spring Grip Cover

Grip Inner Cover

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961323 A0961382 Grip Cover 1➝1 1 13 20
A0961324 A0961383 Grip Inner Cover 1➝1 1 13 19
AA066110 Grip Spring 1➝0 13 34

UNITS AFFECTED:
Not available at time of publication.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 049
Page 3 of 4
Pressure Roller

• UPDATE NO. 3 - PRESSURE LEVERS - The Front

and Rear Pressure Levers have
Front Pressure Lever

been changed to prevent the

Pressure Roller from being
dislodged. New Old

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0964175 A0964174 Front Pressure Lever 1➝1 1 65 31
A0964177 A0964176 Rear Pressure Lever 1➝1 1 65 22

UNITS AFFECTED:
The FT6665 Serial Number cut-in information was not available at time of publication. However, all
FT6645/6655 copiers manufactured after Serial Number A3355040001 and A3365080219 respectively will
have the new style Pressure Levers installed during production.

• UPDATE NO. 4 - AC DRIVE BRACKET, ETC... - Due to part standardization, the Main Board Left
Hinge, Connector Support Plate, DC PCU Connector Bracket and Connector
Bracket shown below have been combined as the AC Drive Bracket.
Main Board Left Hinge

Connector Support Plate Wire Saddle

DC PCU Connector
AC Drive Bracket
Connector Bracket

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0965506 Left Hinge - Main Board 1➝0 95 5
A0965520 Connector Support Plate 1➝0 95 10
A0965522 Connector Bracket - DC PCU 1➝0 95 11
A0965523 Connector Bracket 1➝0 95 12
A0965514 AC Drive Bracket 0 ➝1 3/S 95 35*
11050292 Wire Saddle 0 ➝1 95 115*
* DENOTES NEW ITEM

UNITS AFFECTED:
The FT6665 Serial Number cut-in information was not available at time of publication. However, all
FT6645/6655 copiers manufactured after Serial Number A335508XXXX and A3365080219 respectively will
have the new AC Drive Bracket installed during production.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 049
Page 4 of 4

• UPDATE NO. 5 - DUPLEX LOCK LEVER, ETC... - A mechanism has been added to adjust duplex
side registration. By changing the position of the Duplex Lock Arm [A] in respect
to the Duplex Lock Lever [B], side registration can be adjusted ±1.5mm. At the
same time, the height of the Duplex Harness Bracket [C] has been increased by
2 mm to ensure the engagement of the duplex connector.
Also, to facilitate manufacturing, the Jogger Sensor Bracket has been added as
indicated below.
[A]

11.5 mm ➝ 13.5 mm

[B]

[C]

Jogger Sensor Bracket

Duplex Unit Frame

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0964762 Jogger Sensor Bracket 0➝1 73 45*
A0964886 Duplex Lock Arm 0➝1 73 44*
A0964883 A0964887 Duplex Lock Lever 1➝1 3 73 3
A0964894 A0964895 Duplex Harness Bracket 1➝1 3 75 26
04340080B Philips Tapping Screw - M4 X 8 n ➝ n+2 75
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A335509XXXX, A3365080219 and
A337509XXXX respectively will have the new Jogger Sensor Bracket and Duplex Lock Lever, etc... installed
during production.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 050 2/7/96

APPLICABLE MODEL: FT6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATE

for reproduction of additional bulletins.

GENERAL:
To standardize with other models, the following parts have been changed.

MECHANICAL
Rear End Fence Gear

ELECTRICAL
Lift Lever
Old New

PAPER PATH
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0966655 A0966695 Lift Lever 1→1 1 45 7
A0966658 A0966696 Rear End Fence Gear 1→1 2 45 2

FSM
UNITS AFFECTED:
Not available at time of publication. PARTS

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 051 2/7/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: TONER SCATTER

for reproduction of additional bulletins.

SYMPTOM:
Toner scatter in and around the toner bottle holder.

CAUSE:

MECHANICAL
Toner drops out of the cut-out for the bottle drive gear.

SOLUTION:
Install the Bottle Holder Cover (shown below).

ELECTRICAL
Bottle Holder Cover

PAPER PATH
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

FSM
A0963247 Bottle Holder Cover 0→1 57 37*

A0963241 A0963242 Bottle Stopper 1→1 0 57 2

* DENOTES NEW ITEM

NOTE: The Bottle Stopper has been modified to reduce manufacturing costs. The old stopper and the new
one are interchangeable.
PARTS

UNITS AFFECTED:
Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
OTHER

0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 052 2/7/96

APPLICABLE MODEL: FT6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: TANDEM TRAY DRIVE MECHANISM

for reproduction of additional bulletins.

SYMPTOM:
The tandem Tray timing belt slips on the pulley.

CAUSE:

MECHANICAL
If the paper is not set square in the left tandem tray, excessive friction load is applied to the left tray drive
mechanism.

SOLUTION:
To prevent this, the tensioning method has been changed from the use of a fixed pulley to a movable one.
The spring (#16) has also been changed.

ELECTRICAL
# 30 - Tension Spring

PAPER PATH
# 16

# 24
New Movable Pulley Tensioning Left End Fence

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

FSM
A0966670 Tightener 1→1 3/S 47 24
A0976550 Timing Belt Roller 3/S 47 24
AA060542 Tray Lock Spring 1→1 3/S 47 16
AA060534 Tension Spring 3/S 47 16
PARTS

AA066559 Tension Spring 0→1 3/S 47 30*

* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
OTHER

0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 052 REISSUE ★ 06/28/96

APPLICABLE MODEL: FT6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: TANDEM TRAY DRIVE MECHANISM

for reproduction of additional bulletins.

SYMPTOM:
The tandem Tray timing belt slips on the pulley.

CAUSE:

MECHANICAL
If the paper is not set square in the left tandem tray, excessive friction load is applied to the left tray drive
mechanism.

SOLUTION:
To prevent this, the tensioning method has been changed from the use of a fixed pulley to a movable one.
The spring (#16) has also been changed.

ELECTRICAL
# 30 - Tension Spring

# 16

PAPER PATH
# 24
New Movable Pulley Tensioning Left End Fence

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

FSM
A0966670 Tightener 1→1 3/S 47 24

★ A0976550 Timing Belt Roller 3/S 47 24

AA060542 Tray Lock Spring 1→1 3/S 47 16
AA060534 Tension Spring 3/S 47 16 PARTS

AA066559 Tension Spring 0→1 3/S 47 30*

* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 2
OTHER

NEW machines. OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 053 02/21/96

APPLICABLE MODEL: FT6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: LOWER PICK-UP GUIDE CUSHION

GENERAL:
for reproduction of additional bulletins.

Due to loose fit (mounting play) of the duplex paper end sensor, the sensor may not detect the guide plate.
To firmly position the sensor, a cushion has been added as shown below. This information should be
incorporated into all existing FT6665 Parts Catalog documentation.

MECHANICAL
0~0.5mm
Harness Cover

ELECTRICAL
Guide

1~2mm

Lower Pick-up Guide Cushion

PAPER PATH
Play

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM

FSM
52052777 Cushion - Lower Pick-up Guide 0→1 75 53*
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
PARTS

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
OTHER

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 054 03/20/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
for reproduction of additional bulletins.

The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing Parts Catalog documentation.

MECHANICAL
• UPDATE NO. 1 - SPACER - As the transfer bias roller turns, the ends the of spring (shown below)
may wear against the spacers. To prevent this, a single new type of spacer,
which has replaced the two old type spacers, will be stationary against the spring.
OLD

ELECTRICAL
Spring

PAPER PATH
NEW

REFERENCE

FSM
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963863 Spacer - 4 x 6 x 1 2➝0
63 10
A1763863 Spacer - 4 x 6 x 2 0➝1 1
PARTS

UNITS AFFECTED:
Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
OTHER

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 054
Page 2 of 5

• UPDATE NO. 2 - OPTICS SENSOR ASSEMBLY, etc... - The scanner cable cavity was widened for
smoother cable movement. This was accomplished by modifying the rear optics
cover as shown. Accordingly, the parts listed below have also been modified to
correspond to the size change of the cable cavity.

Scanner Cable
1st Scanner

Rear Optics Cover Cavity

Old New

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AW010033 AW010047 Original Sensor Ass’y - H=3-50 1➝1 0 19 11
AA150337 AA150379 Rear Shielding Mylar 1➝1 3 31 6
A0961792 A1761792 Rear Shielding Bracket 1➝1 3 31 5
A0961821 A1761821 2nd Optics Cover 1➝1 3 19 21
A0961835 A1761835 Optics Shielding Belt 1➝1 3 31 2
A0961842 A1761842 Rear Optics Cover 1➝1 3 19 12
A0961874 A1761874 Harness Guide Plate 1➝1 3 19 8
A0961825 A1761825 Main Optics Cover 1➝1 1 19 5
AA132163 A1761849 Shielding Plate Guide 1➝1 3 19 23
AA150305 Seal - 20 mm 1➝0 19 6
A0961829 A1761829 Cover Rear Angle 1➝1 1 21 21

UNITS AFFECTED:
Not available at time of publication.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 054
Page 3 of 5

• UPDATE NO. 3 - SCANNER DRIVE SHAFT, etc... - The following parts have been changed or
added due to part standardization.
Scanner Cushion

Sensor Bracket

OLD NEW

These connectors are now part

of the Outer Optics Harness

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961921 A0971921 Scanner Drive Shaft 1➝1 0 23 1
A0961925 A0971925 Front Wire Pulley 1➝1 0 23 2
A0971698 Scanner Cushion 0➝2 27 28*
A0071920 A0971746 Exposure Glass Cushion 4➝4 0 19 15
A0965473 A0975473 Outer Optics Harness 1➝1 3 23 31
11026245 11026283 Connector - 2P 1➝1 1 23 117
11026246 11026284 Connector - 3P 1➝1 1 23 118
11026247 11026285 Connector - 4P 1➝1 1 23 120
11026260 11026285 Connector - 3P 1➝1 1 23 119
A0961816 A0971816 Sensor Bracket - Lens Position 1➝1 3 23 21
A0961994 A0971994 Filter Holder 1➝1 0 21 11
AA150336 AA150378 Front Shielding Mylar 1➝1 0 31 7
A0961766 A0971766 Lens Slider 1➝1 0 31 11
AC051013 AC051016 Lens Guide Rod - X 1➝1 0 25 2
AC051015 AC051017 Guide Rod - 3rd Scanner 1➝1 0 29 25
* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 054
Page 4 of 5

• UPDATE NO. 4 - BOTTLE SHIELD - Since it is not needed, the Bottle Shield has been eliminated
from production machines.

REFERENCE
OLD PART NO. DESCRIPTION QTY PAGE ITEM
AA151862 Bottle Shield 1➝0 13 49

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 5 - MAIN SWITCH, etc... - To meet Tier 1 Energy Star requirements, the following
modifications have been applied.

NOTE: For information regarding Energy Star Office Equipment, refer to Publications Bulletin #PUB-066.

1. A main switch with an internal relay is now used for the auto off function.

2. The main switch bracket and the upper left cover have been changed since the is larger than the old
type.

3. To control the relay in the new type switch, the harnesses shown below have been changed.

NOTE: The part number of the DC main harness has not been changed.

4. The Main Board ROMs have been changed.

ARS Harness

Main SW

DC Main Harness
Main Control PCB

Duplex Extension Harness

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 054
Page 5 of 5

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0961300 Decal - Main Switch 1➝0 13 1
A0961294 A0961394 Upper Left Cover 1➝1 3 13 2
A0961330 A1761330 Main Switch Bracket 1➝1 3 93 6
12041545 12042421 Main Switch 1➝1 3 93 105
A0965409 A1755409 ARS Harness 1➝1 1 13 41
A0965431 A0965433 Duplex Extension Harness 1➝1 1 95 24
A0955442 A0955113 Main Control Board-115V (A095) 1➝1 3 105 *
A0965442 A0965113 Main Control Board-115V (A096 / A097) 1➝1 3 105 *
A0965151 A0965155 IC - AM27C040-150DC 1➝1 3 105 1
A0965153 A0965157 IC - AM27C010-120DC 1➝1 3 105 2

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3356410371, A3366410281 and
A3376410001 respectively will have the new style Main Switch, etc... installed during production.

• UPDATE NO. 6 - PARTS CATALOG ADDITION - Add the AC Drive Board for the FT6665 copier to
your FT6645/6655/6665 Parts Catalog as indicated below.

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0975175 AC Drive Board - 115V (A097) 1 89 20
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 055 03/29/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SPRING HOOK PLATE

for reproduction of additional bulletins.

GENERAL:
To ensure that the shutter lever goes all the way up when a customer releases the lever, a second Spring

MECHANICAL
(#33) and the hook plate (# 36) have been added. This information should be incorporated into all existing
FT6645/6655/6665 Parts Catalog documentation.

Spring Hook Plate (#36)

(secured using two-sided tape)

ELECTRICAL
Newly Added

PAPER PATH
Existing Spring (# 33)

Shutter Lever side view - assembled

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM

FSM
A0963249 Spring Hook Plate 0→1 57 36*
AA060262 Spring 1→2 57 33
* DENOTES NEW ITEM
PARTS

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3355500591, A3365500001 and
A337550XXXX respectively will have the Spring Hook Plate and additional Spring installed during production.
OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 055 REISSUE ★ 06/04/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SPRING HOOK PLATE

for reproduction of additional bulletins.

GENERAL:
To ensure that the shutter lever goes all the way up when a customer releases the lever, the following

MECHANICAL
modifications have been made. This information should be incorporated into all existing FT6645/6655/6665
Parts Catalog documentation.

TEMPORARY COUNTERMEASURE:
A second spring (#33) and the hook plate (# 36) have been added.

ELECTRICAL
Spring Hook Plate (#36)
(secured using two-sided tape)

Newly Added

PAPER PATH
Existing Spring (# 33)

Shutter Lever side view - assembled

FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM
A0963249 Spring Hook Plate 0→1 57 36*
PARTS

AA060262 Spring 1→2 57 33

* DENOTES NEW ITEM

UNITS AFFECTED:
OTHER

All FT6645/6655/6665 copiers manufactured after Serial Number A3355500591, A3365500001 and
A337550XXXX respectively will have the Spring Hook Plate and additional Spring installed during production.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 055 REISSUE
Page 2 of 2

★ PERMANENT COUNTERMEASURE:

Instead of the Spring Hook Plate, a tab has been added on the toner bottle holder to connect the spring.

The Spring Hook Plate has

been removed

Tab

Toner Bottle Holder New Type

NOTE: The part number for the Toner Bottle Holder has not been changed.

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A335602XXXX, A336602XXXX and
A337602XXXX respectively will have the new style Toner Bottle Holder installed in place of the Spring Hook
Plate during production.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 056 03/29/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: LIFT MOTOR JOINT

GENERAL:
for reproduction of additional bulletins.

To increase durability, the material of the Lift Motor Joint has been changed from resin to metal. This
information should be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

MECHANICAL
REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0966169 A0976169 Lift Motor Joint 3 ➝ 3 - FT6645 1 85 7
2 ➝ 2 - FT6655/6665 87 8

ELECTRICAL
UNITS AFFECTED:
Not available at time of publication.

FSMPAPER PATH
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
PARTS

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.
OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 057 03/29/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: ENERGY STAR MODIFICATION (DETAILS)

for reproduction of additional bulletins.

GENERAL:
To conserve energy, the copier automatically turns "OFF" 90 minutes after the last copy job has been
completed. The details of the machine operation are as follows:

MECHANICAL
• AUTO OFF MODE To automatically turn "OFF" the copier, a new type of Main Switch with an
incorporated coil is used. When the CPU drops CN112-B9 from +24V to 0, the
Main Switch contact is opened. The Point-to-Point wiring diagram is shown
below.

ELECTRICAL
PAPER PATH
NOTE: 1. The Auto Off mode is a mandatory standard feature of Energy Star compliant

FSM
equipment. The weekly timer feature for the FT6645/6655/6665 is no longer available.
2. For part number information, refer to Tech Service Bulletin No. 6645/6655/6665 - 054
(Update No. 5)

PARTS

• AUTO DUPLEX MODE To save paper resources, the following have been selected as factory
default settings and can be changed with User Program 5.

• Copiers with a document feeder and sorter will produce two sided copies from an even number of
originals
• Copiers with a recirculating document handler and finisher will produce two sided copies from one sided
OTHER

originals

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 057
Page 2 of 5

• ANTI-CONDENSATION HEATER CONNECTORS

To meet very strict power consumption specifications in Auto "OFF" mode, the anti-condensation heater
connectors are kept disconnected at the factory. At the time of installation, check the humidity conditions at
the customer site and connect the heater connectors if necessary.

Lightening Arrestor PCB

CN5

CN4

CN2

CAUTION: Unplug the copier power cord before setting the anti-condensation heater connectors.
This is because even though the main switch may be turned "OFF", AC current is still
supplied to the anti-condensation circuit.

• INSTRUCTION SHEET

An additional explanation sheet has been added to the Operating Instructions. Please make copies of
pages 3, 4 and 5 of this bulletin and add them to the Operating Instructions for all Energy Star Compliant
FT6645/6655/6665 copiers.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 057
Page 3 of 5

ENERGY SAVING INFORMATION

As an Energy Star Partner, we have determined that this copier model meets Energy Star
Guidelines for energy efficiency.

This product was designed to reduce the environmental impact associated with copying equipment by
means of energy saving feature such as AUTO OFF and DUPLEX DEFAULT MODES.

About The Energy Saving Features of this Copier

Auto Off Mode
NOTE: There is an explanation of Auto Off mode in your Operating Instructions. The explanation of Auto
Off mode described below is a supplement/correction of that given in your Operating Instructions.

NOTE: The Weekly Timer is not available on this copier because of the Auto Off mode.

To conserve energy, this copier model automatically turns off 90 minutes after the last copying job has been
completed. Power consumption is reduced from 0.25 kW (standby) to less than 0.01 kW.

To exit the Auto Off Mode, turn on the main switch. The main switch for this copier has three positions, press
it all the way and hold for 1 - 2 seconds.

Changing The Auto Off Timer

1. Press the Clear Modes key.

2. Press the Clear/Stop key for more than 3 seconds until the User
Tools Menu appears on the touch panel display.

3. Touch the [1] Auto reset/ Auto off key.

4. Adjust the Auto off timer following the instructions on the display.

• Time can be adjusted from 1 to 120 minutes in 1 minute steps.

• You cannot cancel the Auto off mode. The [OFF] key cannot
be selected.

5. To return to the User Tools Menu, touch the [Menu] key.

6. To exit from the User Tools condition, touch the [Exit] key.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 057
Page 4 of 5

Duplex Default Mode

NOTE: There is an explanation of the Duplex mode in your Operating Instructions. The explanation of the
Duplex mode described below is a supplement/correction to that given in your Operating
Instructions.

The factory (Default) setting in Menu 5 (Set operation modes) of the User Tools has been set at "PROGRAM
5" rather than "NORMAL". This allows copy modes stored in Program 5 be set as the default. (For detail,
refer to Page 16 of your Operating Instruction Book.)

To save paper resources, the following Duplex mode has been selected as the factory (default) setting using
Program 5:

• Copiers with the document feeder and the sorter stapler are set for two sided copies from an even
number of originals.
• Copiers with the recirculating document handler and the finisher are set for two sided copies from one
sided originals.

Canceling The Duplex Default Mode

To cancel the Duplex Default mode, store one-sided copy mode in Program 5 as follows:

1. Press the Clear Modes key.

2. Touch the [Duplex/Series Copies] key to cancel the duplex

mode.

Note: The illustration on the right shows the display for

the document feeder and the sorter stapler system.

3. Press the Program key.

4
4. Touch the [Store Program] key.

5. Touch the [5] key.

Then, the display shows "Program 5 has been stored. Do you
want to revise the program?".

6. Touch the [Yes] key to overwrite a new program. 5

7. Touch the [5] key again to enter a new program.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 057
Page 5 of 5

Changing Duplex Default Mode

To change a duplex mode set at the factory as a default to an another duplex mode you need as a default,
select the appropriate duplex mode and overwrite it in Program 5 as follows;

1. Press the Clear Modes key.

2. Touch the [Duplex/Series Copies] key to cancel the duplex mode. Then, touch the [Duplex/Series
Copies] key again and select the appropriate duplex mode as a default.

• For the sorter stapler system, you can select either "Two sided copies from an odd number of
originals" or "Two sided copies from two sided originals".
• For the finisher system, you can select "Two sided
copies from two sided originals".

Note: The illustration on the right shows the display for

the document feeder and the sorter stapler system

3. Press the Program key.

4. Touch the [Store Program] key.

5. Touch the [5] key.

Then, the display show "Program 5 has been stored. 4
Do you want to revise the program?"

6. Touch the [Yes] key to overwrite a new program.

7. Touch the [5] key again to enter a new program.

Recycled Paper
Please contact your sales or service representative for recommended recycled paper types that may be
used in this copier.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 058 06/04/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

GENERAL:
for reproduction of additional bulletins.

The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing Parts Catalog documentation.

MECHANICAL
• UPDATE NO. 1 - OPERATION PANEL ASSEMBLY, etc.. - To meet CE Mark Standards, the Key
Board PCB has been changed. The grounding wires have been incorporated
into the new type board and the keytop sheets have been changed. Also, to
increase the durability of the Start Key, the design has been changed so that the
Key Board will not receive excessive pressure when the Start Key is pressed as
shown in the illustration below. Accordingly, the Start Key, the Operation Panel
Case, and the Key Board have been changed.

ELECTRICAL
Important:
Due to a change of vendors, the old type parts are no longer available as service parts. Please replace
these parts as a set.
Start key

PAPER PATH
Existing Studs

New Stud

FSM
Start key
Operation Panel Case

Key Board
PARTS

New Old

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 058
Page 2 of 2

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961461 A0961465 Operation Panel Ass’y - LT 1➝1 1 17 *
A0961462 A0961466 Operation Panel Ass’y - A4 1➝1 1 17 *
A0961486 A0961489 Operation Panel Case - LT 1➝1 3/S 17 1
A0961487 A0961490 Operation Panel Case - A4 1➝1 3/S 17 1
A0961491 A0961499 Keytop - Start 1➝1 3/S 17 2
A0961506 A0961522 Right Keytop Sheet 1➝1 3 17 9
A0961507 A0961523 Left Keytop Sheet 1➝1 3 17 10
A0961517 A0961525 Key Board - 115V 1➝1 3/S 17 18
A0961518 A0961526 Key Board - 220 / 230V 1➝1 3/S 17 18
A0961511 Grounding Harness - 1 1➝0 17 14
A0961521 Grounding Harness - 2 1➝0 17 15

UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A33509XXXX, A336509XXXX and
A337509XXXX respectively will have the new style Operation Panel parts installed during production.

• UPDATE NO. 2 - PARTS CATALOG CORRECTION - Add the following part to your Parts Catalog.

REFERENCE
PART NO. DESCRIPTION QTY PAGE ITEM
A0964937 Driven Roller Guide 3 75 39
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 059 06/04/96

APPLICABLE MODEL: FT6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: RDH ORIGINAL AUTO COUNT DOES NOT WORK

for reproduction of additional bulletins.

SYMPTOM:
When making one sided to two sided duplex copies on the Energy Star compliant machines, the RDH will

MECHANICAL
not count the number of originals (faulty Even original mode).

CAUSE:
Software.

FIELD COUNTERMEASURE:
1. Turn "ON" the copier Main Switch with the RDH installed.

ELECTRICAL
2. Press One Side ➝ Two Sided duplexing key. This key is the default selection key on the Energy Star
machines, however, it must be pressed again for this operation.

3. Press the User Program key.

4. Store the current mode in the program #5.

PAPER PATH
5. Turn the machine "OFF" and "ON".

6. Confirm that the RDH counts the number of originals. Confirmation can be done by pressing the
Check Modes key. If "Even" is not displayed on the Duplex/Series Copies tag, the correction has
been performed successfully.

NOTE: 1. If the default mode is changed to single-side copying or two-sided to two-sided duplexing,
selecting the one-sided to two-sided mode will not cause the above mentioned problem.

FSM
2. The above procedure is to be done one time only per machine. The corrected data will be
kept on the RAM board.

UNITS AFFECTED:
All Energy Star compliant FT6655/6665 copiers configured with an RDH. PARTS

FIELD COUNTERMEASURE:
The software has been modified to correct the above mentioned symptom. The new ROMs are as follows:

A0965155B and A0965157B

OTHER

UNITS AFFECTED:
Not available at time of publication.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 060 07/25/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: DISCOLORING (YELLOWING) OF THE LEFT DOOR

for reproduction of additional bulletins.

GENERAL:
It has been determined that silicone oil gas causes the Left Door to become discolored. The Left Door Seal

MECHANICAL
has been added as shown to prevent the gas from leaking onto the left door. This information should be
incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

ELECTRICAL
Left Door

FSMPAPER PATH
Left Door Seal

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
PARTS

A1761328 Left Door Seal 0➝1 13 61*

* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 060 REISSUE ★ 11/08/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: DISCOLORING (YELLOWING) OF THE LEFT DOOR

for reproduction of additional bulletins.

GENERAL:
It has been determined that silicone oil gas causes the Left Door to become discolored. The Left Door Seal

MECHANICAL
has been added as shown to prevent the gas from leaking onto the left door. This information should be
incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

ELECTRICAL
Left Door

FSMPAPER PATH
Left Door Seal

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
PARTS

A1761328 Left Door Seal 0➝1 13 61*

* DENOTES NEW ITEM

★ UNITS AFFECTED:
All FT6645/6655/6665 copiers manufactured after Serial Number A3356450267, A3366450012 and
OTHER

A3376450072 respectively will have the new style Left Door Seal installed during production.
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 061 07/25/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: RDH ORIGINAL AUTO COUNT DISABLED

for reproduction of additional bulletins.

SYMPTOM:
When making one sided to two sided duplex copies on the Energy Star compliant machines, the RDH will

MECHANICAL
not count the number of originals (faulty Even original mode).

CAUSE:
Software.

FIELD COUNTERMEASURE:

ELECTRICAL
1. Turn "ON" the copier main switch with the RDH installed.
2. Press One Side → Two Sided duplexing key. This key is default selection key on the Energy Star
machines, however, it must be pressed again for this operation.
3. Press the User Program key.
4. Store the current mode in the program #5.
5. Turn the machine "OFF" and "ON".
6. Visually confirm that the RDH counts the number of originals. Confirmation also can be done by pressing

PAPER PATH
the Check Modes key. If "Even" is not displayed on the Duplex/Series Copies tag, the correction has been
successful.

NOTE:

1. If the default mode is changed to single-side copying or two-sided to two- sided duplexing, selecting the
one-sided to two-sided mode will not cause the problem.
2. The above procedure is only necessary once per machine. The corrected data will be kept on
the RAM board.

FSM
PRODUCTION COUNTERMEASURE:
The software has been updated to correct the above mentioned symptom. The Part Numbers for the
software are as follows:
A0965155B
PARTS

A0965157B

UNITS AFFECTED:
All FT6645/6655/6665 copiers ,manufactured after Serial Number A3356430280, A3366430322 and
A3376440001 respectively will have the updated software installed during production.
OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 062 09/27/96

APPLICABLE MODEL: FT6645/6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

for reproduction of additional bulletins.

GENERAL:
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information

MECHANICAL
should be incorporated into all existing Parts Catalog documentation.

• UPDATE NO. 1 - SIDE FENCE PAD - For better adhesion, the double-sided tape on the pad has
been extended to the edges.

REFERENCE

ELECTRICAL
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0297904 Pad - CFF 1→0
41 2
A0966554 Side Fence Pad 0→1 1

UNITS AFFECTED:

PAPER PATH
All FT6645/6655/6665 copiers will utilize the new Side Fence Pad as a service part only.

• UPDATE NO. 2 - OPERATION PANEL ASSEMBLY - The touch panel, which is composed of two
layers, has been changed from glass-to-glass to film-to-glass structure for
standardization with other models. Accordingly, the part number of the Operation
Panel Assembly has been changed.

FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0961465 A0961455 Operation Panel Assembly - LT 1→1 0 17 *
AW500016 AW500020 Touch Panel 1→1 17 19 PARTS

UNITS AFFECTED:
All FT6645/6655/6665 copiers will utilize the new style Operation Panel as a service part only.
INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured aft er the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 062
Page 2 of 3

• UPDATE NO. 3 - GUIDE ROLLER, ETC... - The following parts have been changed due to parts
standardization.

OLD NEW 20 110

21
38

40

115

19 38

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
A0961961 A1761965 Slider Bracket - 3rd Scanner 1→1 3 29 19
A0961963 A1761962 Slider Shaft 1→1 3 29 21

52091694 A1761964 Guide Roller 1→1 1 29 20

52051694 Adjusting Cam - Start Lever n → n-1 29 22*

54465832 Connector Guide Pin n → n+1 29 38*

AA143732 Adjusting Screw 0→1 29 39*

09524008W Philips Screw - M4 x 8 n → n-1 29 109
05740060E Hexagon Headless Set Screw - n → n-1 29 111
M4 x 6
09514008W Philips Screw with Flat Washer - n → n-1 29 112
M4 x 8
03140060B Philips Pan Head Screw - M4 x 6 0→1 29 115*
AA066277 Guide Roller Spring 0→1 29 40*
* DENOTES NEW ITEM

UNITS AFFECTED:
All FT6645/6655/6665 copiers will utilize the above mentioned parts as service parts only.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 062
Page 3 of 3

• UPDATE NO. 4 - FT6665 OIL SUPPLY ROLLER ASSEMBLY - The Oil Supply Roller Assembly is
available as a service part.

Oil Supply Roller Assembly

REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
A0964080 Oil Supply Roller Assembly 1 65 59*
* DENOTES NEW ITEM
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 063 10/15/96

APPLICABLE MODEL: FT6655/6665

COPY QUALITY
Note: This copy intended as master of original

SUBJECT: FALSE MISFEED FROM 1.5K LCT

for reproduction of additional bulletins.

SYMPTOM:
A misfeed occurs from the 1.5K LCT, with no paper in it.

MECHANICAL
Paper Stuck
End here Bottom
Feeler Plate

CAUSE:
The Paper End Feeler is caught by the bottom plate and cannot
drop all the way down into the cut-out. Thus, the Paper End Sensor
does not detect the paper end condition.

ELECTRICAL
15 mm
FIELD COUNTERMEASURE:
File the shaded area of the bottom plate to prevent
the feeler from being caught.

2 mm

NOTE: Make sure that the edges are filed smooth.

FSM
PARTS
OTHER
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NJH NGfEGfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG CORRECTION

for reproduction of additional bulletins.

GENERAL:
The following Parts are no longer used. This information should be incorporated into all existing

‰ MECHANICAL
FT6645/6655/6665 Parts Catalog documentation.

REFERENCE
OLD PART NUMBER DESCRIPTION QTY PAGE ITEM
AA150333 Seal - 0.19 X 14 X 74 1→0 21 22

‰
1→0

ELECTRICAL
AA150334 Seal - 0.19 X 40 X 48 21 23

‰
‰
„
‰ FSMPAPER PATH
PARTS
OTHER
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NJI NHfEHfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
79&.)'8U# 4%687#'%8%03+#94(%8)7
Note: This copy intended as master of original
for reproduction of additional bulletins.

GENERAL:

‰ MECHANICAL
Do to a vendor change, the 2 megabyte ROM’s, will be replaced with 4 megabyte ROM’s .
This information should be incorporated into all existing 6645/6655/6665 Parts Catalog documentation.

„ ELECTRICAL
REFERENCE

‰ PAPER PATH
PART NO. OLD DESCRIPTION NEW DESCRIPTION QTY INT PAGE ITEM

A0967702 2 Meg - AM27C1024 - 150 AC 1 1 17 21

4 Meg - M27C4002 - 12F1 1 1 17 21

‰
UNITS AFFECTED:

FSM
Not available at time of publication.

„ PARTS

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S
‰

previously modified, use the new part numbers individually.

OTHER
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 066 04/14/97

APPLICABLE MODEL: FT6645/6655/6665

qCOPY QUALITY
SUBJECT: PARTS CATALOG CORRECTIONS
Note: This copy intended as master of original

GENERAL:
for reproduction of additional bulletins.

The Parts Catalog Corrections are being issued for all FT6645/6655/6665 Parts Catalog. This information
should be incorporated into all existing Parts Catalog documentation.

q MECHANICAL
INCORRECT
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AB013802 Gear - 30Z 1 73 28

q
GB013035 Gear - 28Z 2 73 40

ELECTRICAL
AB010089 Gear - 35Z 1 73 41

q
CORRECT

PAPER PATH
REFERENCE
PART NUMBER DESCRIPTION QTY PAGE ITEM
AB013802 Gear - 30Z 1 73 41
GB013035 Gear - 28Z 1 73 28

q
AB010089 Gear - 35Z 1 73 40

n
q FSM
PARTS
OTHER
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NJK NIfNJfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SC520
for reproduction of additional bulletins.

SYMPTOM:

„ MECHANICAL
SC520 appears during a long copy run.

CAUSE:
The fuser lubricant may become viscous during a long copy run.

SOLUTION:
To prevent this, the production machines have been modified as follows:

„ ELECTRICAL
1. The material of the bushing has been changed.

2. The bushing has been assembled from the inside of the holders.

3. The retaining rings have been removed and the grooves for the retaining rings on the lower cleaning
roller have been eliminated.

‰ PAPER PATH
Lower Cleaning Roller Old Bushing Pressure Roller Cleaning Roller

New Bushing

Old Bushing
Retaining Ring

‰
New Bushing

FSM
Retaining
Ring
OLD NEW

„
NOTE: 1. The old lower cleaning roller is no longer available.
PARTS

2. These (new style) parts are available as an assembly (A0974242).

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
‰

1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 067
Page 2 of 2

REFERENCE
OLD PART NEW PART DESCRIPTION QTY INT PAGE ITEM
NO. NO.
AA082063
Bushing - 4 X 7 1→1 3/S 65 52
AE031024
AE042012 Lower Cleaning Roller
1→1 3/S 65 51
AE042023 Pressure Roller Cleaning Roller
0720025B Retaining Ring - M2.5 n → n-2 3/S 65 101

A0974242 Lower Cleaning Roller Assembly 65 60*

* DENOTES NEW ITEM

UNITS AFFECTED:
Not available at time of publication.
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NJL NIfNJfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: MAGNETIC CLUTCH STOPPER

for reproduction of additional bulletins.

GENERAL:
To prevent breakage, the shape of the Magnetic Clutch Stopper has been changed. This information should

‰ MECHANICAL
be incorporated into all existing FT6645/6655/6665 Parts Catalog documentation.

‰
‰ ELECTRICAL
PAPER PATH
Stopper

OLD NEW

‰ FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0962604 A0962616 Magnetic Clutch Stopper 1→1 1 35 10

„
UNITS AFFECTED:
PARTS

Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
‰

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NJM NIfNJfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: SC361 / UPPER DRUM SHIELD

for reproduction of additional bulletins.

SYMPTOM:

„ MECHANICAL
SC361

CAUSE:
When the drum reverses rotation, the Upper Shield (seal) may wrap around the drum. If this should occur,
SC361 will be recorded in the SP Data (SC Count).

‰ ELECTRICAL
SOLUTION:
To prevent this from occurring, the length of the Upper Drum Shield (seal) has been reduced by 4mm.

‰ PAPER PATH
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0962302 A0962304 Upper Drum Shield 1→1 1 59 10
A0962251 A0962256 Upper Drum Unit 1→1 1 59 *

‰ FSM
UNITS AFFECTED:
Not available at time of publication. „ PARTS

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
‰

1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NKN NJfEGfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

„ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: FIELD SERVICE MANUAL - INSERT

for reproduction of additional bulletins.

GENERAL:

‰ MECHANICAL
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin
package contains 1 set of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

‰
• Table of Contents vi Additional Information

ELECTRICAL
• 5-130 Additional Information

‰
„
‰
‰ PAPER PATH
FSM
PARTS
OTHER
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NKE NJfEGfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

for reproduction of additional bulletins.

• UPDATE NO. 1 - PLATEN COVER HARNESS - To facilitate assembly, the function of the Platen
Cover Harness has been combined with the Outer Optics Harness.

‰ MECHANICAL
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0965474 Platen Cover Harness 1-0 23 30
1
A0975473 Outer Optics Harness 1-0 23 31

‰
A1755473 Outer Optics Harness 0-1 23 31

ELECTRICAL
UNITS AFFECTED:
Not available at time of publication.

‰
UPDATE NO. 2 - SEPARATION ROLLER STAY - Due to parts standardization, the following parts

PAPER PATH
have been changed.

NOTE: Since the location of the position sensor bracket on which the separation roller stay is installed has
been moved 5 mm towards the rear, the 3 parts listed below must be replaced at the same time.
Also, the old parts will no longer be available.

REFERENCE

‰
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM

FSM
A0966303 A1766303 Separation Roller Stay 3-3 3/S 39 44
A0966338 A1766338 Separation Guide 3-3 3/S 39 22
A0966337 A1766337 Paper Feed guide 3-3 3/S 39 14
„
UNITS AFFECTED:
PARTS

Not available at time of publication.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
‰

NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
OTHER

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 071
Page 2 of 2

• UPDATE NO. 3 - CLEANING BLADE SPRING - To improve the cleaning ability for the transfer
belt, the pressure of the cleaning blade spring has been increased.

NOTE: To prevent the Cleaning Blade from flipping, please apply plenty of setting powder or toner on the
edge of the new blade at installation.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA066239 AA066290 Cleaning Blade Spring 1-1 1 63 38

UNITS AFFECTED:
Not available at time of publication.

• UPDATE NO. 4 - POSITION SENSOR BRACKET - Curled paper may be misfed due to delayed
detection by the position sensor. To correct this, the following parts have been
modified:

1. The configuration of the position sensor bracket has been changed. The height of the position
sensor has been raised by 1mm.

2. The notch holes (A) for the Separation Guide and the Paper Feed Guide Position Sensor have been
enlarged.
NOTE: When installing the new Position Sensor Bracket, you must also replace the Separation
Guide and the Paper Feed Guide if the Feeler comes in contact with the Position Sensor Bracket.

3. A retaining ring has been added to decrease the play in the thrust direction.

Paper Feed Guide

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0966321 A1766321 Position Sensor Bracket 1-1 1 39 50
07200040B Retaining Ring - M4 n-n+1 39 106

UNITS AFFECTED:
Not available at time of publication.
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NKF NLfFMfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: FIELD SERVICE MANUAL - INSERT

for reproduction of additional bulletins.

GENERAL:
The Field Service Manual page(s) listed below must be replaced with the page(s) supplied. Each bulletin

‰ MECHANICAL
package contains 1 set of replacement pages.

PAGES:
The revised areas have been highlighted by an arrow ⇒

• 5-48 Updated Information

‰
• 5-49

ELECTRICAL
Updated Information
• 5-51 Updated Information

‰
„
‰
‰ PAPER PATH
FSM
PARTS
OTHER
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U####JJHIfJJIIfJJJI#g#NKG NLfFMfMK
%440-'%&0)#13()0U# *8JJHIfJJIIfJJJI

‰ COPY QUALITY
Note: This copy intended as master of original

SUBJECT: PARTS CATALOG UPDATES

for reproduction of additional bulletins.

GENERAL:

‰ MECHANICAL
The following Parts Updates are being issued for all FT6645/6655/6665 Parts Catalogs. This information
should be incorporated into all existing Parts Catalog documentation.

• UPDATE NO. 1 - HOT ROLLER - To increase the durability of the Hot Roller, a special glue has
been used to adhere the Teflon layer to the new style Hot Roller. To distinguish it
from the old type, the two grooves on the Hot Roller shaft have been removed.

‰ ELECTRICAL
Grooves : Two → Zero

‰ PAPER PATH
REFERENCE

‰
OLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM

FSM
AE011020 AE011042 Hot Roller 1-1 65 10

NOTE: The old and new style parts are interchangeable.

UNITS AFFECTED: „
All FT6645/6655/6665 will utilize the new style Hot Roller as a service part only.
PARTS

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
‰

Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S
OTHER

previously modified, use the new part numbers individually.

Continued...
Tech Service Bulletin No. 6645/6655/6665 - 073
Page 2 of 2

• UPDATE NO 2 - OIL SUPPLY ROLLER - Due to part standardization, the Oil Supply Roller has
been changed.

For your reference, the current part numbers for the Oil Supply Rollers are as follows:

FT6645/6655
REFERENCE
CURRENT PART NO. DESCRIPTION QTY PAGE ITEM
AE040006 Oil Supply Roller (A095/A096) 1 65 38

FT6665
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY PAGE ITEM
AE040009 AE040013 Oil Supply Roller (A097) 1 65 38
TECHNICAL SERVICE BULLETIN
CUSTOMER SERVICE GROUP

BULLETIN NUMBER: 6645/6655/6665 - 074 10/31/97

APPLICABLE MODEL: FT6645/6655/6665

qCOPY QUALITY
Note: This copy intended as master of original

SUBJECT: DUPLEX ENTRANCE JAMS

for reproduction of additional bulletins.

SYMPTOM:
Paper with a degree of curl may get caught in the Inverter Weight, resulting in duplex entrance jams.

q MECHANICAL
CAUSE:
The Inverter Weight bounces slightly.

SOLUTION:
Four (4) pieces of mylar have been added to the Inverter Weight as shown.

q
# 39
P/N A1764449
# 37

ELECTRICAL
P/N A1764447

# 38
P/N A1764448

# 28
P/N A0964441
↓
P/N A1764442

n
# 36

PAPER PATH
P/N A1764445

Mylar

Inverter
weight

q FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM n
A0964441 A1764442 Inverter Weight 1-1 1 71 28
PARTS

A1764445 Small Inverter Guide Mylar: Short 0-1 71 36*

A1764447 Small Inverter Guide Mylar: Long 0-1 71 37*
A1764448 Large Inverter Guide Mylar: Short 0-1 71 38*
A1764449 Large Inverter Guide Mylar: Long 0-1 71 39*
q

* DENOTES NEW ITEM

OTHER

UNITS AFFECTED:
All FT6645/6655/6665 copiers will utilize the above mentioned parts as service parts only.

U JJHIfJJIIfJJJI g NKH + NFfFNfML

U
JJHIfJJIIfJJJI

‰
COPY QUALITY
Note: This copy intended as master of original

SUBJECT: DUPLEX ENTRANCE JAMS

for reproduction of additional bulletins.

SYMPTOM:
Paper with a degree of curl may get caught in the Inverter Weight, resulting in duplex entrance jams.

‰
CAUSE:

MECHANICAL
The Inverter Weight bounces slightly.

SOLUTION:
Four (4) pieces of mylar have been added to the Inverter Weight as shown.

‰
„ ELECTRICAL
PAPER PATH
+

‰ FSM
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
„
A0964441 A1764442 Inverter Weight 1-1 1 71 28
PARTS

A1764445 Small Inverter Guide Mylar: Short 0-1 71 36*

A1764447 Small Inverter Guide Mylar: Long 0-1 71 37*
A1764448 Large Inverter Guide Mylar: Short 0-1 71 38*
‰

A1764449 Large Inverter Guide Mylar: Long 0-1 71 39*

* DENOTES NEW ITEM
OTHER

UNITS AFFECTED:
All FT6645/6655/6665 copiers will utilize the above mentioned parts as service parts only.
8)',2-'%0#7)6:-')#&900)8-2
'97831)6#7)6:-')#+6394

&900)8-2#291&)6U #JJHIfJJIIfJJJI#h#NKI###############################################NGfEKfML
%440-'%&0)#13()0U###*8JJHIfJJIIfJJJI

‰
SUBJECT: TRANSFER BELT UNIT

COPY QUALITY
Note: This copy intended as master of original

GENERAL:
for reproduction of additional bulletins.

Due to a request from the field, the Transfer Belt Assembly and the Transfer Belt Casing Assembly have
been registered as service parts. The following Parts Updates are being issued for all FT6645/6655/6665
Parts Catalogs.

‰
* 47

MECHANICAL
‰
ELECTRICAL
‰
*46

PAPER PATH
‰
SM
REFERENCE
NEW PART NO. DESCRIPTION QTY PAGE ITEM „
46 *
PARTS
A0963800 Transfer Belt Assembly 1 63
A0963801 Transfer Belt Casing Assembly 1 63 47 *

* DENOTES NEW PART

‰
OTHER
'97831)6#7)6:-')#+6394
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U JJHIfJJIIfJJJI#g#NKJ NGfEKfML
%440-'%&0)#13()0U *8JJHIfJJIIfJJJI

‰
COPY QUALITY
SUBJECT: ANTISTATIC SPACER
Note: This copy intended as master of original
for reproduction of additional bulletins.

GENERAL:
The material and shape of the Antistatic Spacer has been changed to improve it’s durability. The following
Parts Corrections are being issued for all FT6645/6655/6665 Parts Catalogs.

‰
MECHANICAL
‰
ELECTRICAL
OLD NEW

‰
PAPER PATH
REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA120064 AA120088 Antistatic Spacer 2 0 65 19

‰
SM
UNITS AFFECTED:
Serial Number cut-in not available at time of publication.

„
PARTS

INTERCHANGEABILITY CHART:
0 OLD and NEW parts can be used in both OLD and 2 NEW parts CAN NOT be used in OLD machines.
NEW machines. OLD parts can be used in OLD and NEW machines.
1 NEW parts can be used in OLD and NEW machines. 3 OLD parts CAN NOT be used in NEW machines.
‰

OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
OTHER

3/S
previously modified, use the new part numbers individually.
D F E M s B O s F Bs
O s B s D
O s F Bs E M D FE s
D F E M O s B
MO Ds EBs MOD s FE Bs M OD FE s
O F Bs D F E M D s EB

TECHNICAL
M D s E M O s B s O F Bs
O s F s O D F E s M D s E
M E B s B O F s
Bs MOD s F Bs M OD s FE s M ODs FEB
s O D F E sM D E B M s B s
B
E s M Ds EB MO s F s O D FE s
B
D FE s M Ds EB
E B MO s F Bs O s O F Bs
F Bs D
O s F E M D E B M s
E M B s O s F Bs D FE s
F D E M O
s EBs MO s F Bs O D FE s M Ds EB
F
F s D F E M D s E B O s
Ds FEB s MO Ds EBs MO s F Bs M OD FEB
s B O s F s O D F E M D s E
OD s FE BULLETINS
B s M D
O s F Bs E B M D s
BULLETINS B s
E s M Ds O F
D F E M O F O
MO Ds EBs MOD s FE Bs M ODs FEB s M Ds
F O
MO Ds EBs MOD s FE Bs M ODs FEB s M Ds
F O
MO Ds EBs MOD s FE Bs M ODs FEB s M D
O s F on
Click sthe D
Directory
O F Eyou M
wish to
D sview. E B M O
M D E B M s B s O s F Bs
O s F s D F E M D E M O
M D E B MO s B s O s F Bs
O F
M Ds EBs MO s F Bs D E M D FE s M
O F Bs D FE s M Ds EB O
M D s E M O s B O F s
O F D E M s B
M Ds EBs MO s F Bs O D FE
s EB
O F s O D F E M D
M Ds EB M s B s O s F
F D E M D
MO Ds EBs MO s F Bs O s F E
O F s D F E M D
M Ds EB MO s B s O sF
F D E M
MO Ds EBs MO s F Bs O D
O s F Bs O D FE s M Ds
M D FE M Ds EB MO
O
M Ds FEB MO s F Bs s D
O D E M O
M D s s
B M O F s
O F E D s E B MO
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNE NHfFGfML
%440-'%&0)#13()0U The chart listed below shows the Last Bulletin
####+)78)82)6#FIHI(fFIII(fFIJI( Number issued for the A095/A096/A097 series.
####6-'3,#JJHIfJJIIfJJJI Bulletin Cross Reference
####7%:-2#MHINfMIINfMJIN Ricoh Group Companies Last Bulletin No.
Gestetner N/A
Ricoh 076
Savin 9450 033
Savin 9550 038
Savin 9650 014

SUBJECT: BUSHING OIL SUPPLY ROLLER

Note: This copy intended as master original

„
for reproduction of additional bulletins.

GENERAL:

PARTS
To improve durability, the material of the Bushing-Oil Supply Roller and Bushing - 4x6x10 has been
changed. The part number of the Fusing Units have also been changed.
The following parts corrections are being issued for all A095/A906/A907 Parts Catalogs.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AE031014 AE031026 Bushing – Oil Supply Roller 2 1 65 39
AE031018 AE031027 Bushing – 4x6x10 2 1 65 56
A0974007 A0974023 Fusing Unit – 220/230V (A097) 1 0 65 ∗
A0974009 A0974021 Fusing Unit – 115V (A097) 1 0 65 ∗

INTERCHANGEABILITY CHART:
0 OLD and NEW parts can be used in both OLD and 2 NEW parts CAN NOT be used in OLD machines.
NEW machines. OLD parts can be used in OLD and NEW machines.
1 NEW parts can be used in OLD and NEW machines. 3 OLD parts CAN NOT be used in NEW machines.
OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines.
3/S Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
previously modified, use the new part numbers individually.

RICOH GROUP COMPANIES

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNF NIfFLfML
%440-'%&0)#13()0U
####+)78)82)6#h#FIHI(fFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN

SUBJECT: PARTS CATALOG UPDATES

Note: This copy is intended as a master original

GENERAL:

„
for reproduction of additional bulletins.

PARTS
The following parts updates being issued for all A095, A096 and A097 Parts Catalogs.

• UPDATE 1: MAIN MOTOR / OZONE FAN MOTOR – Due to parts

standardization, the Main Motor and the Ozone Fan Motor
have been changed. When installing the new Ozone Fan
Motor use new Tapping Bind Screws P/N 04524016B

Main Motor Ozone Fan Motor

106 ¤ý114

Page 81 Page 89

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AX060072 Main Motor–DC21W (A095/A096) 1→0 - 81 23
AB033048 Timing Pulley – 31/32Z 1→0 - 81 22
AX060125 DC Motor– DC208W (A095/A096) 0→1 1 81 23
AX060095 Main Motor – DC24V27W (A097) 1→0 - 81 23
AB033048 Timing Pulley – 31/32Z 1→0 - 81 22
AX060127 DC Motor – 27W (A097) 0→1 1 81 23
05740050E Hexagon Headless Set Screw-M4x5 n→n-1 81 104
A0962110 A1762110 Ozone Fan Motor 1→1 0 89 13
04140082B Binding Self Tapping Screw – M4x8 n→n-3 - 89 106
04524016B Tapping Bind Screw –M4x16 n→n+3 3 89 ∗114

∗ New Item number

Continued…

RICOH GROUP COMPANIES '328630#23T#FLM

Tech Service Bulletin No. A095/A096/A097 – 002
Page 2 of 2

• UPDATE 2: EXPOSURE SCREWS – To prevent the screws from

loosening, the Screws for the Exposure Lamp Harness and the
Front Wire Pulley have been changed to the Nylock type.

104
104 → 29 104 → 33
A1761888 A1761926

Scanner Drive Shaft

Page 27 Page 23
Front Wire Pulley
Exposure Lamp Harness

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
05740050W Hexagon Headless Set Screw – M4x6 n→n-2 - 23 104
A1761926 Hexagon Headless Set Screw – M4x6 0→2 1 23 ∗33
09513012B Phillips Screw with Flat Washer M3x12 n→n-1 - 27 104
A1761888 Phillips Screw with Flat Washer M3x14 0→1 1 27 ∗29
* Indicates new Item number

• UPDATE 3: FRAME BUSHING – Due to part standardization the

Bushing – M4 has been changed.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AA080156 AA080241 Bushing – M4 6→6 0 101 5

UNITS AFFECTED:
A095/A096/A097 Serial Number cut-in not available at time of publication.

INTERCHANGEABILITY CHART:
0 OLD and NEW parts can be used in both OLD and 2 NEW parts CAN NOT be used in OLD machines.
NEW machines. OLD parts can be used in OLD and NEW machines.
1 NEW parts can be used in OLD and NEW machines. 3 OLD parts CAN NOT be used in NEW machines.
OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines.
3/S Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or units
previously modified, use the new individual part numbers.
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNG NMfEEfML
%440-'%&0)#13()0U
####+)78)82)6#h#FIHI(fFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN
Note: This copy is intended as a master original

SUBJECT: ENTRANCE SEAL / TRANSFER BELT

„
for reproduction of additional bulletins.

GENERAL:

PARTS
The following parts updates are being issued for all A095, A096 and A097 Parts Catalogs.

• UPDATE 1: ENTRANCE SEAL – A high pitched noise may occur if the loop part of the
Development Unit Entrance Seal is warped. If the loop part of the Seal
comes in contact with the Drum, the seal vibrates and a high pitched noise
is transmitted. To prevent the vibration, the length of the Loop Seal has
been shortened by 0.5mm (19.0mm →18.5mm). Please update your Parts
Catalog with the updated Entrance Seal.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963098 A0963103 Entrance Seal 1 0 53 4

• UPDATE 2: TRANSFER BELT – To improve the cleaning of the Transfer Belt, the
material used for the coating layer of the Transfer Belt surface has been
changed. Due to this change, the degree of belt cracking has been
decreased, paper becoming dirty from the surface of the belt has
decreased and the amount of toner adhering to the Transfer Belt has
decreased. Please update your Parts Catalog with the updated Transfer
Belt

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963852 A1763870 Transfer Belt 1 0 63 1

INTERCHANGEABILITY CHART:
0 OLD and NEW parts can be used in both OLD and 2 NEW parts CAN NOT be used in OLD machines.
NEW machines. OLD parts can be used in OLD and NEW machines.
1 NEW parts can be used in OLD and NEW machines. 3 OLD parts CAN NOT be used in NEW machines.
OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines.
3/S Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
previously modified, use the new part numbers individually.

RICOH GROUP COMPANIES CONTROL NO. 304

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNH NMfGNfML
%440-'%&0)#13()0U
####+)78)82)6#h#FIHI(fFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN
SUBJECT: PARTS CATALOG UPDATES
Note: This copy is intended as a master original

GENERAL:

„
for reproduction of additional bulletins.

PARTS
The following parts updates are being issued for all A095, A096 and A097 Parts Catalogs.

• UPDATE 1: CHARGE CORONA UNIT – A new style Charge Corona Unit has been
released. To prevent rusting of the Screw Shaft and the Grounding Plate, a
material more resistant to rust has been used. These parts should be
replaced as a set to prevent wear on the area that comes in contact with the
Screw Shaft and the Grounding Plate, or order the entire Charge Corona Unit
Ass’y.

Charge Corona Unit

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
AD004069 AD004092 Charge Corona Unit 1 0 59 9
A0962061 A1762061 Screw Shaft 1 3 59 12 *
A0962054 A1762054 Grounding Plate 1 3 59 17 *
* Denotes that these parts should be replaced as a set.
Continued…

RICOH GROUP COMPANIES CONTROL NO. 310

Tech Service Bulletin No. A095/A096/A097 – 004
Page 2 of 2

• UPDATE 2: FRONT COVER PLATE & HARNESS COVER – The shape of the Paper
Bank Harness Cover and the Paper Bank Front Side Plate have been
changed. Due to the modification of these parts, the old style parts will no
longer be supplied, therefore replace these parts as a set.

29 Paper Bank Front Side Plate Ass’y

Old New

27 Paper Bank Harness Cover

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0966181 A1766181 Front Side Plate-P/B 1 1 97 29 *
A0966110 A1766110 Harness Cover 1 1 97 27 *
* Denotes that these parts should be replaced as a set.

INTERCHANGEABILITY CHART:
0 OLD and NEW parts can be used in both OLD and 2 NEW parts CAN NOT be used in OLD machines.
NEW machines. OLD parts can be used in OLD and NEW machines.
1 NEW parts can be used in OLD and NEW machines. 3 OLD parts CAN NOT be used in NEW machines.
OLD parts CAN NOT be used in NEW machines. NEW parts CAN NOT be used in OLD machines.
3/S Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
previously modified, use the new part numbers individually.

U NMIfNMJfNMKhNNI ENfEGfML
U
hFIHIfFFIIIfFIJI
h
JJHIf
JJIIf
JJJI
hMHINfMIINfMJIN

SUBJECT: ENTRANCE SEAL

Note: This copy is intended as a master original

n
for reproduction of additional bulletins.

PARTS
GENERAL:

To reduce/eliminate the high-pitched noise from the Development Unit, the glued section of the Loop Seal on
which glue is applied has been reduced. This will decrease the contact pressure of the Loop Seal on the
drum. This is the second modification of the entrance seal. The following Parts Corrections are being issued
for all A095/A096/A097 Parts Catalogs.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0963103 A2293092 Entrance Seal 1 0 53 4

RICOH GROUP COMPANIES

CONTROL NO. 312

U NMIfNMJfNMKgNNJ EEfNJfML
U
hFIHIfFIIIfFIJI
h
JJHIfJJIIfJJJI
hMHINfMIINfMJIN

SUBJECT: BLACK LINES ON COPIES

Note: This copy is intended as a master original

SYMPTOM:
for reproduction of additional bulletins.

nCOPY QUALITY
Short black lines called “Medaka” appear on copies.

CAUSE:
If a large number of duplex copies are made, the temperature in the copier will rise as the paper passes
through the Fusing section. Paper dust may also contribute to this symptom but the degree will vary
depending upon the type of paper used. The mixture of toner and paper dust is attracted to the Drum’s
surface. Since the temperature in the copier is higher, this mixture becomes softer and makes it more
difficult for the Cleaning Blade and Brush to completely remove it from the Drum.

SOLUTION:
Install the Lubricant Bar (A1763515) if short black lines appear or if Medaka is a chronic symptom. See
Installation Procedure provided below.

INSTALLATION PROCEDURE:
Before installing the Lubricant Bar, the Developer should be replaced. Also, the OPC Drum should be
replaced or cleaned completely.

1. Prepare the Lower Drum Unit (P/N: A1763510); by removing the Drum Unit Harness (P/N:
A1755440 from this unit.

2. Remove the Drum Unit from the copier, then remove the Lower Drum Unit, and remove the Drum Unit
Harness (P/N: A0965440) from this unit. Then, install this Harness on the Lower Drum Unit (P/N:
A1763510)

CAUTION: If the Drum Harness is not replaced with P/N: A0965440, the Charge Power
Pack will be damaged.

Note: The Drum Unit Harness color (two lines) for the Pre-transfer Lamp is different between the models:
P/N A0965440: white/white (A095/A096/A097)
P/N A1755440: white/blue (A175/A176/A177)

3. Replace the Lower Drum Unit with P/N A1763510.

4. Change the VP data from 0V (default) to – 40V using the SP Mode adjustment 1 (Page 8, Item8).

Continued…

RICOH GROUP COMPANIES CONTROL NO. 314

Tech Service Bulletin No. A095/A096/A097– 006
Page 2 of 2

NOTE: Since the ID Sensor pattern becomes lighter due to lubrication, the toner concentration in the
Developer becomes much higher, causing toner scattering or dirty background.

The parts listed below are PM parts, therefore they should be replaced every 120K copies. Both parts are
included in the Lower Drum Unit. Please follow the procedure listed below when replacing the Lubricant Bar.

The replacement procedure for the lubricant bar is as follows.

1. Remove the Cleaning Release lever [A] (1 screw).

2. Remove the Spring [B].
3. Remove the Cam Gear-35Z [C] (1 E-ring, Spacer M-6).
4. Remove the Cleaning Brush Bushing [D] (1 screw).
5. Remove the Cleaning Blade Bracket Ass’y [E].
6. Remove the Lubricant Bar Ass’y [F] (3 screws).
7. Remove the Lubricant Bar Seal [G] (3 screws) and replace it.
8. Remove the Stopper [H] and replace the Lubricant Bar [I].

[E]
[I]
[B]
[C]
[A]

[F] [H]
[D]
[G]

REFERENCE
NEW PART NUMBER DESCRIPTION QTY PAGE ITEM
A1763515 Lubricant Bar 1 61 59
A1763522 Lubricant Bar Seal 1 61 60
A1763518 Stopper 1 61 61
8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNK NKfNJfMM
%440-'%&0)#13()0U
####+)78)82)6#h#FIHIfFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN

SUBJECT: MAIN SWITCH (for 110/230V only)

Note: This copy is intended as a master original

„
GENERAL:
for reproduction of additional bulletins.

PARTS
The material used to make the Main Switch has been changed, to prevent damage to the Main Switch when
using an alkali solvent or petroleum based cleaner. The following part update is being issued for all A095,
A096 and A097 Parts Catalogs. Please update your Parts Catalogs with the following information.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
12041545 12042501 Main Switch 1 1 93 105

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

RICOH GROUP COMPANIES CONTROL NO. 365

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNL NKfNJfMM
%440-'%&0)#13()0U
####+)78)82)6#h#FIHI(fFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN

SUBJECT: EXPOSURE LAMP HARNESS

Note: This copy is intended as a master original

„
GENERAL:
for reproduction of additional bulletins.

PARTS
The following part update is being issued for all A095, A096 and A097 Parts Catalogs. Please update your
Parts Catalogs with the following information.

REFERENCE
OLD PART NO. NEW PART NO. DESCRIPTION QTY INT PAGE ITEM
A0965477 A2475477 Exposure Lamp Harness 1 0 27 14

UNITS AFFECTED:
Service parts only.

INTERCHANGEABILITY CHART:
OLD and NEW parts can be used in both OLD and NEW parts CAN NOT be used in OLD machines.
0 NEW machines. 2 OLD parts can be used in OLD and NEW machines.
NEW parts can be used in OLD and NEW machines. OLD parts CAN NOT be used in NEW machines.
1 OLD parts CAN NOT be used in NEW machines. 3 NEW parts CAN NOT be used in OLD machines.
Must be installed as a set on units manufactured prior to the S/N cut-in. On units manufactured after the S/N cut-in or
3/S previously modified, use the new part numbers individually.

RICOH GROUP COMPANIES CONTROL NO. 365

8)',2-'%0#7)6:-')#&900)8-2
&900)8-2#291&)6U %NMIf%NMJf%NMK#g#NNM NKfFNfMM
%440-'%&0)#13()0U
####+)78)82)6#h#FIHI(fFIII(fFIJI(
####6-'3,#h#*8JJHIfJJIIfJJJI
####7%:-2#h#MHINfMIINfMJIN

SUBJECT: GEAR – 32Z

Note: This copy is intended as a master original

„
GENERAL:
for reproduction of additional bulletins.

PARTS
The following part updates are being issued for all A095, A096 and A097 Parts Catalogs. Please update
your Parts Catalogs with the following information.

REFERENCE
PART NUMBER OLD DESCRIPTION NEW DESCRIPTION QTY PAGE ITEM
st nd
AB013777 Gear – 32Z Gear – 32Z (1 and 2 Feed) 2 39 28
rd
AB013779 Gear – 32Z Gear – 32Z (3 Feed) 1 39 28

RICOH GROUP COMPANIES CONTROL NO. 368